Aerostatic thrust bearing and method of aerostatically supporting a thrust load in a scroll compressor

ABSTRACT

A scroll compressor includes a first scroll member, a second scroll member, and an aerostatic thrust bearing. The aerostatic thrust bearing forms a layer of gas between the second scroll member and a fixed supporting member to support the second scroll member as the second scroll member rotates and/or orbits. Also disclosed is a method of supporting a rotating/orbiting scroll member in a scroll compressor. The method including supplying pressurized gas to an aerostatic thrust bearing such that a layer of gas is formed between the rotating/orbiting scroll member and a fixed supporting member.

FIELD

This disclosure relates to bearings in scroll compressors and methods ofproviding lubrication in scroll compressors.

BACKGROUND

Scroll compressors utilize intermeshing scroll members to compress afluid. Heating, ventilation, air conditioning, and refrigeration systems(“HVACR”) may utilize scroll compressors to compress a gaseousrefrigerant. A first scroll member can be intermeshed with a secondscroll member. The second scroll member is rotated or orbited(non-fixed) relative to the first scroll member. During operation, thesecond scroll member is rotated or orbited such that volumes of gas(e.g., refrigerant) are compressed between the intermeshed scrollmembers. A thrust bearing can be provided to support the second,non-fixed, scroll member in the axial direction. A crankshaft within thescroll compressor may rotate the second, non-fixed, scroll member, andbearings can support the crankshaft while it rotates.

SUMMARY

A scroll compressor utilizes two scroll members with intermeshing spiralwraps to compress a gas, such as a refrigerant. A first scroll memberhas a spiral wrap. A second scroll member has a spiral wrap and isrotated or orbited relative to the first scroll member such that volumesof gas are trapped between the intermeshed spiral wraps of the first andsecond scroll members. The trapped volumes of gas are then compressed asthe second scroll member rotates or orbits relative to the first scrollmember. As the gas is compressed between the first and second scrollmembers, the gas can exert a force in the axial direction. This forcemay also be referred to as a thrust load.

In an embodiment, the scroll compressor includes a fixed supportingmember for supporting the second scroll member in the axial direction.The scroll compressor also includes an aerostatic thrust bearing tosupport the second scroll member in the axial direction. The aerostaticthrust bearing supports the second scroll member such that the thrustload of the second scroll member does not significantly change thesecond scroll member's intermeshed position with the first scroll memberin the axial direction. The aerostatic thrust bearing supports thesecond scroll member such that the axial ends of the spiral wrap of thesecond scroll member stay in contact with a baseplate of the firstscroll member. The aerostatic thrust bearing includes a surface of thesecond scroll member, a surface of the fixed supporting member, and agas distributing structure. In an embodiment, the fixed supportingmember is a structure within the scroll compressor that has a fixedposition relative to the second scroll member. The fixed supportingmember also includes a surface that faces the baseplate. In anembodiment, the fixed supporting member is part of a bearing housing.The gas distributing structure in an embodiment may be located on thesurface of the second scroll member and/or the surface of the fixedsupporting member.

In an embodiment, the gas distributing structure is supplied with apressurized gas and distributes the pressurized gas between the secondscroll member and fixed supporting member over a surface area. Forexample, a gas distributing structure is a porous material thatdistributes the received pressured gas over said surface area. Duringthe normal operation of the scroll compressor, the thrust load isapplied to the second scroll member. The thrust load on the secondscroll member could push the surface of the fixed supporting memberagainst the surface of the second scroll member. However, in anembodiment, the gas distributing structure distributes a flow ofpressurized gas between the surfaces of the second scroll member and thefixed supporting member. As the pressurized gas is distributed betweenthe surfaces of the second scroll member and the fixed supportingmember, the flowing pressurized gas prevents the surfaces fromcontacting (e.g., during normal operation).

In an embodiment, the aerostatic thrust bearing includes a gasdistributing structure with an inner radial seal and an outer radialseal that are each located on the second scroll member or the fixedsupporting member. The gas distributing structure also includes one ormore openings in the second scroll member or the fixed supportingmember. During operation, the gas distributing structure distributespressurized gas into a space between the second scroll member and fixedsupporting member in an axial direction and between the radial seals ina radial direction. During the normal operation of the scrollcompressor, the thrust load on the second scroll member applies a forcein the axial direction. However, in an embodiment, the flow ofpressurized gas is into the space between the second scroll member andfixed supporting member. As the pressurized gas flows between throughthe space between the surfaces of the second scroll member and the fixedsupporting member, the flowing pressurized gas prevents the surfacesfrom contacting (e.g., during normal operation), and the radial sealsprovide a flow resistance to the pressurized gas easily flowing out fromthe space between the surfaces of the second scroll member and the fixedsupporting member.

In an embodiment, the thrust load pushes the second scroll memberagainst the distributed pressurized gas flowing between the secondscroll member and the fixed supporting member. As such, the distributedpressurized gas is formed into a layer (e.g., a thin film) between thesecond scroll member and the fixed supporting member. As the secondscroll member pushes on the flowing layer of pressurized fluid, thesecond scroll member compresses the layer of flowing pressurized gas.For the second scroll member to move in the axial direction, the secondscroll member in an embodiment further compresses the layer of flowingdistributed pressurized gas. As the layer of pressurized gas is alreadycompressed (e.g., pressurized), a large amount of force corresponds to asmall amount of compression. In such a manner, the layer of flowingpressurized gas dampens and/or absorbs the thrust load of the secondscroll member. Accordingly, the aerostatic thrust bearing supports thesecond scroll member in the axial direction. In an embodiment, the gasdistribution structure utilizes a working fluid (e.g., a refrigerant, arefrigerant blend, or the like) of the compressor as the pressurizedgas.

In an embodiment, a method is directed to supporting a rotating ororbiting scroll member in a scroll compressor. In the scroll compressor,a fixed supporting member is positioned within the scroll compressorsuch that a surface of the fixed supporting member faces a surface ofthe rotating or orbiting scroll member. The method in an embodimentincludes providing a gas distributing structure on the surface of thefixed supporting member or the surface of the rotating or orbitingscroll member, supplying pressurized gas to the gas distributingstructure, and the gas distributing structure forming a layer of gasbetween the rotating or orbiting scroll member and the fixed supportingmember. The layer of gas is configured to support a thrust load of therotating or orbiting scroll member.

In an embodiment, a scroll compressor utilizes one or more aerostaticbearings to support the crankshaft as it rotates. In an embodiment, oneor more aerostatic radial bearings support the crankshaft in its radialdirection as it rotates. An aerostatic radial bearing for supporting thecrankshaft includes a radial surface (e.g., a journaled surface) of thecrankshaft, a surface of a fixed supporting member that faces thecrankshaft, and a gas distributing structure. In an embodiment,pressurized gas is supplied to the gas distributing structure and theaerostatic radial bearing forms a layer of flowing pressurized gasbetween the radial surface of the crankshaft and the surface of thefixed supporting member that faces the crankshaft. The layer of gassupports the crankshaft in the radial direction as it rotates. In anembodiment, the gas distributing structure for the aerostatic radialbearing may be located on the radial surface of the crankshaft and/orthe surface of the fixed supporting member.

In an embodiment, a crankshaft aerostatic thrust bearing supports acrankshaft in the axial direction as it rotates. A crankshaft aerostaticthrust bearing includes an axial end surface of the crankshaft, asurface facing the axial end surface of the crankshaft, and a gasdistributing structure. In an embodiment, pressurized gas is supplied tothe gas distributing structure such that the crankshaft aerostaticthrust bearing forms a layer of gas between the axial end surface of thecrankshaft and the surface facing the axial end surface. The layer ofgas supports the crankshaft in the axial direction as it rotates. In anembodiment, the gas distributing structure for the crankshaft aerostaticthrust bearing may be located on the axial surface of the crankshaftand/or the axial surface of the fixed supporting member.

In an embodiment, an aerostatic radial bearing is provided around aneccentric end of the crankshaft that engages with the second scrollmember. The aerostatic radial bearing includes a radial surface of theeccentric end of the crankshaft (e.g., a journaled surface of theeccentric end), a surface of the second scroll member (e.g., an innersurface of a sleeve of the second scroll member), and a gas distributingstructure. In an embodiment, pressurized gas is supplied to the gasdistributing structure such that the aerostatic radial bearing forms alayer of gas between the outer radial surface of the outer surface ofthe eccentric end and the surface of the second scroll member. Theaerostatic radial bearing can allow the eccentric end to transfer itsmovement due to rotation to the second scroll member withouttransferring its rotation. In an embodiment, the gas distributingstructure for the aerostatic radial bearing for the eccentric end of thecrankshaft may be located on the surface of the second scroll memberand/or the radial surface of the eccentric end of the crankshaft.

In an embodiment, for example as described above, one or more of thebearings of the bearings of the scroll compressor may utilizepressurized gas instead of other lubricants (e.g., oil) such that thecompressor is an oil-free scroll compressor. In an embodiment, forexample as described above, all of the bearings of the scroll compressormay utilize pressurized gas instead of other lubricants (e.g., oil) suchthat the compressor is an oil-free scroll compressor. In an embodiment,an oil-free scroll compressor may utilize the working fluid (e.g., arefrigerant, a refrigerant blend, or the like) of the compressor as thepressurized fluid.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a schematic diagram of a refrigerant circuit including acompressor, a condenser, an expansion device, and an evaporator.

FIG. 2 shows a cross section of an embodiment of a vertical,single-stage scroll compressor including aerostatic thrust bearingincluding a gas distributing structure in a bearing housing.

FIG. 3A shows an enlarged sectional view of the aerostatic thrustbearing in the vertical, single-stage scroll compressor shown of FIG. 2.

FIG. 3B shows a schematic view of the aerostatic thrust bearing in anembodiment of a scroll compressor.

FIG. 4 shows a downward view of the bearing housing and the gasdistribution structure in an embodiment of a scroll compressor.

FIG. 5 shows a downward view of the bearing housing and the gasdistributing structure in an embodiment of scroll compressor.

FIG. 6 shows a sectional view of an end portion of an orbiting scrolland corresponding bearing housing in an embodiment of a scrollcompressor.

FIG. 7 shows a cross sectional view of an embodiment of a vertical,single-stage scroll compressor including an aerostatic thrust bearingincluding a gas distributing structure in an orbiting scroll.

FIG. 8 shows a cross sectional view of an embodiment of an oil-free,vertical, single-stage scroll compressor including aerostatic bearingsin the orbiting scroll and the crankshaft.

FIG. 9 shows a partial cross sectional view of an aerostatic radialbearing from the view 9-9 of FIG. 8.

FIG. 10A shows an enlarged view of the crankshaft aerostatic thrustbearing of FIG. 8 including an embodiment of an axial dynamic seal.

FIG. 10B shows an enlarged view of the crankshaft aerostatic thrustbearing of FIG. 8 including an embodiment of a radial dynamic seal.

FIG. 11 shows a cross sectional view of an embodiment of an oil-free,vertical, single stage scroll compressor including aerostatic bearingsto support the crankshaft and the orbiting scroll.

FIG. 12 shows a cross sectional view of an embodiment of an oil-free,vertical, single-stage compressor including aerostatic bearings in theorbiting scroll and the crankshaft.

FIG. 13 shows a cross sectional view of an embodiment of a vertical,single-stage scroll compressor including an aerostatic thrust bearingthat includes a gas distributing structure and radial seals.

FIG. 14 shows an enlarged sectional view of the aerostatic thrustbearing in the vertical, single-stage scroll compressor shown of FIG. 2.

FIG. 15 shows a cross sectional view of an embodiment of an oil-free,vertical, single stage scroll compressor including aerostatic bearingsto support the crankshaft and an aerostatic thrust bearing to support anorbiting scroll that includes radial seals to support an orbitingscroll.

DETAILED DESCRIPTION

Scroll compressors compress gas between the intermeshing spiral wraps oftheir scroll members. As the scroll members compress a gas between theirspiral wraps, the compressed gas may push on the non-fixed scroll memberin the axial direction. This pushing force, also referred to as a thrustload, may cause the non-fixed scroll member to become incorrectlypositioned in the axial direction and/or contact other internal parts ofthe scroll compressor (e.g., a fixed supporting member, a bearinghousing supporting the crankshaft). When incorrectly positioned, theends of the spiral wrap of the non-fixed scroll member may not form aseal with the baseplate of the fixed scroll member as the non-fixedscroll member is not in contact with the fixed scroll member. Therotation or orbiting of the non-fixed scroll member can amplify thethrust load, especially towards the outer diameter of the baseplate ofthe non-fixed scroll member.

Some previous scroll compressors have utilized pressurized oil in thespace behind the non-fixed scroll member to support the non-fixed scrollmember in the axial direction. Some previous scroll compressors haveutilized an oil-based thrust bearing between the fixed supporting memberof the scroll compressor (e.g. a bearing housing) and the non-fixedscroll member to support the non-fixed scroll member in the axialdirection. In some such previous scroll compressors, the thrust bearingtypically included additional piece(s) that were placed between thenon-fixed scroll member and fixed supporting member. These previousthrust bearings also require a flow of pressurized oil to support thenon-fixed scroll member.

Some previous scroll compressors have utilized aerodynamic air bearings,which may also be referred to as thrust foil bearings, to support thenon-fixed scroll member. An aerodynamic air bearing forms a dynamiccushion of air between the non-fixed scroll member and a supportstructure to support the non-fixed scroll member. Aerodynamic airbearings rely on the movement (e.g. the rotation or orbiting) of thenon-fixed scroll member to provide support, which results in contactbetween the non-fixed scroll member and a support structure whenstopping and starting of the scroll compressor. However, an aerodynamicair bearing provides weaker support relative to the area of its bearingsurface (e.g. the surface of bearing that faces the supportingstructure) as it requires a bearing surface that includes non-activesurfaces.

Disclosed herein are embodiments of scroll compressors that utilize anaerostatic thrust bearing to support the non-fixed scroll member. In anembodiment, the aerostatic thrust bearing is supplied with a pressurizedgas. The aerostatic thrust bearing includes a gas distributing structurethat distributes the pressurized gas between the non-fixed scroll memberand the fixed supporting member of the scroll compressor. In such amanner, a layer of flowing pressurized gas is formed to support thenon-fixed scroll member and the thrust load. The aerostatic thrustbearing is an “aerostatic” type bearing as it forms a layer of flowinggas between its bearing surfaces from an incoming flow of gas. An“aerostatic” type bearing is different from an “aerodynamic” typebearing.

In an embodiment, the aerostatic thrust bearing provides a support forthe non-fixed scroll member without requiring contact with the non-fixedscroll member. This is advantageous as the aerostatic thrust bearing inan embodiment provides lower frictional losses because it does notrequire any solid-to-solid contacts to provide support for the non-fixedscroll member. Further, the friction between the layer of flowingpressurized gas and the non-fixed scroll member is less than thefriction between a liquid lubricant and the non-fixed scroll member.Less friction creates less shear stress in the lubricant. The aerostaticthrust bearing in an embodiment is advantageous as less energy is lostdue to friction and/or shear stress of the pressurized gas than a thrustbearing that utilizes a liquid lubricant (e.g., oil),In an embodiment,the aerostatic thrust bearing is supplied with pressurized gas tosupport the non-fixed scroll member. In an embodiment, the flow ofpressurized gas is not dependent upon the rotation of the non-fixedscroll member. As such, the support provided by the aerostatic thrustbearing in an embodiment is not dependent upon the rotation of thenon-fixed scroll member or a crankshaft to provide support for thenon-fixed scroll member. The aerostatic thrust bearings are advantageousas they can provide support during the starting and stopping of thecompressor. Further, in an embodiment, the aerostatic thrust bearing isadvantageous as it does not require non-active surfaces to support thenon-fixed scroll member.

An embodiment of a scroll compressor may also include one or moreaerostatic bearings to support the crankshaft of the compressor as itrotates. An embodiment may also include an aerostatic radial bearing foran end (e.g., an eccentric end) of the crankshaft that engages thenon-fixed scroll member. Each aerostatic bearing may include a gasdistributing structure. Each aerostatic bearing may utilize apressurized gas to form a layer or layer of gas that supports thecrankshaft as it rotates. In such a manner, the scroll compressor may bean oil-free scroll compressor. In an embodiment, the scroll compressormay be a scroll compressor for an HVACR system and the pressurized gasmay be a refrigerant.

An HVACR system can be used to cool or heat one or more conditionedspaces. A HVACR system may utilize a working fluid (e.g., refrigerant)in a circuit to cool some type of process fluid (e.g., air, water). Forexample, an HVACR system in some instances will cool an area byperforming work on a refrigerant that is in a heat exchange relationshipwith air. The cooled air may then be ventilated to an area to cool thearea.

FIG. 1 is a schematic diagram of a heat transfer circuit 1, according toan embodiment. The heat transfer circuit 1 generally includes acompressor 2, a condenser 3, an expansion device 4, and an evaporator 5.In an embodiment, the heat transfer circuit 1 can be modified to includeadditional components. For example, in an embodiment, the heat transfercircuit 1 can include an economizer heat exchanger, one or more flowcontrol devices, a receiver tank, a dryer, a suction-liquid heatexchanger, or the like.

The heat transfer circuit 1 can generally be applied in a variety ofsystems (e.g., a vapor compression system) utilized to control anenvironmental condition (e.g., temperature, humidity, air quality) in aspace, which is typically referred to as a conditioned space. Exemplarysystems including a heat transfer circuit 1 include, but are not limitedto, HVACR systems, transportation refrigeration systems, and the like.

The components of the heat transfer circuit 1 are fluidly connected. Theheat transfer circuit 1 can be configured as a cooling system (e.g., afluid chiller of an HVACR, an air conditioning system, and the like)that can be operated in a cooling mode, and/or the heat transfer circuit1 can be configured to operate as a heat pump system that can run in acooling mode and a heating/defrost mode.

The heat transfer circuit 1 as described applies known principles of gascompression and cooling. The heat transfer circuit can be configured toheat or cool a process fluid (e.g., water, air). In an embodiment, theheat transfer circuit 1 may represent a chiller that cools a processfluid such as water or the like. In an embodiment, the heat transfercircuit 1 may represent an air conditioner and/or heat pump thatincludes a process fluid such as air or the like.

During the operation of the refrigerant circuit 1, a working fluid(e.g., refrigerant) flows into the compressor 2 from the evaporator 5 ata relatively lower pressure in a gaseous state. The compressor 2compresses the gas into a high pressure state, which also heats the gas.After being compressed, the relatively higher pressure and highertemperature gas flows from the compressor 2 to the condenser 3. Inaddition to the refrigerant flowing through the condenser 3, an externalfluid (e.g., external air, external water, chiller water, and the like)also flows through the condenser 3. In accordance with known principles,the external fluid absorbs the heat from the working fluid as it flowsthrough the condenser 3. The working fluid condenses to liquid and thenflows into the expansion device 4. The expansion device 4 reduces thepressure of the working fluid. The reduced pressure allows the workingfluid to expand and be converted to a mixed vapor and liquid state. Therelatively lower temperature, vapor/liquid working fluid then flows intothe evaporator 5. A process fluid (e.g., air, water, and the like) alsoflows through the evaporator 5. In accordance with known principles, theworking fluid absorbs heat from the process fluid as it flows throughthe evaporator 5. As the working fluid absorbs heat, the working fluidbecomes evaporates to vapor. The working fluid then returns to thecompressor 2. The above-described process continues while the heattransfer circuit 1 is operated, for example, in a cooling mode.

FIG. 2 shows a cross section of an embodiment of a scroll compressor 10having an aerostatic thrust bearing for supporting a non-fixed scrollmember 14. The aerostatic thrust bearing includes a gas distributingstructure 64 located on the surface of bearing housing 58. Although theembodiments shown herein are vertical, single-stage scroll compressors,it should be appreciated that the descriptions and features describedherein may be applied to multi-stage scroll compressors, inclined scrollcompressors, and/or horizontal scroll compressors as well. Further, itshould be appreciated that the description and features described heremay be applied to scroll compressors with co-orbiting scrolls orco-rotating scrolls.

The scroll compressor 10 shown in FIG. 2 may also be, for example, thecompressor 2 in the refrigerant circuit 1 as described above for FIG. 1.

Applying known aspects of scroll compressor compression, a scrollcompressor 10 may utilize two intermeshing scroll members 12, 14 tocompress volumes of gas (e.g., trapped volume 16, trapped volume 17)between their respective intermeshing spiral wraps 18, 20. The scrollcompressor 10 may have a non-fixed scroll member 14 and fixed scrollmember 12. The fixed scroll member 12 is a scroll member that is in afixed position within the external housing 22 and is not configured ordesigned to be rotated or moved (e.g., orbited) during the operation ofthe scroll compressor 10. The fixed scroll member 12 may be referred toas a fixed scroll, a non-orbiting scroll, or a stationary scroll. In anembodiment, the fixed scroll 12 can be directly attached to the externalhousing 22 of the scroll compressor 10. The fixed scroll 12 has abaseplate 13 and a spiral wrap 18 that projects in a direction towardsthe non-fixed scroll 14.

The non-fixed scroll member 14 is a scroll member that engages with anend of a crankshaft 24. During operation of the scroll compressor, thenon-fixed member is orbited relative to the fixed scroll member 12. Thenon-fixed scroll member 14 may also be referred to as an orbitingscroll, a rotating scroll, or the like. The orbiting scroll 14 has abaseplate 26 and a spiral wrap 20 that projects in a direction towardsthe fixed scroll 12. The baseplate 26 may also have a back surface 28that faces in a direction that is generally opposite of the spiral wrap20.

The fixed scroll 12 and the orbiting scroll 14, as shown in FIG. 2, arein their correct intermeshed positions relative to each other. Whenpositioned correctly, the axial end of the spiral wrap 20 (e.g., the endof the spiral wrap not connected to the baseplate 26) of the orbitingscroll 14 contacts the baseplate 13 of the fixed scroll 12. Similarly,the axial end of the spiral wrap 18 (e.g. the end of the spiral wrap 18not connected to the baseplate 13) of the fixed scroll 12 contacts thebaseplate 26 of the orbiting scroll 14. This contact creates a sealbetween the spiral wraps 18, 20 and the opposing baseplates 13, 26,respectively, in the axial direction. This seal prevents the compressedgas from escaping from one trapped volume to another (e.g., from trappedvolume 16 to trapped volume 17). In a vertical scroll compressor 10 asshown in FIG. 2, the axial direction is also the vertical direction.

In an embodiment, the axial end of one or both of the spiral wraps 18,20 may include a tip seal to help encourage sealing between the spiralwraps and the opposing baseplate 13, 26. However, if the orbiting scroll14 is moved in the axial direction, the described sealing of the trappedvolumes (e.g., trapped volume 16, trapped volume 17) may not besufficient. Typically, the movement of the fixed member is not a concerndue to its fixed position. The loss of this sealing can lead to, forexample, a loss of efficiency of the scroll compressor 10 or theinability of the scroll compressor 10 to compress the inlet gas.

In an embodiment, a scroll compressor 10 can include a coupling device,such as the Oldham coupling 30 shown in FIG. 2. In an embodiment, thecoupling device (e.g. Oldham coupling 30) and a radial bearing 48 can beutilized so that the radial movement of the eccentric end 56 (relativeto the crankshaft 24) is transferred to the orbiting scroll 14 withouttransferring the rotational movement. Accordingly, the orbiting scroll14 orbits relative to the fixed scroll 12 without rotating in anembodiment.

It should be understood that the spiral wraps 18, 20 do not have to beperfectly spiral (e.g., Archimedean spiral, logarithmic spiral) in anembodiment. For example, in an embodiment, the curvature of the spiralwraps 18, 20 may be non-constant and/or an end portion of one (or both)of the spiral wraps 18, 20 may be non-spiral (e.g., a majority of thespiral wrap 18 may be spiral but an end portion may project radially).

In an embodiment, the external housing 22 of the scroll compressor 10has an upper portion 32A and a lower portion 32B. In an embodiment, thevolume contained within the upper portion 32A may be defined as theupper volume 34A of the scroll compressor 10 and the volume containedwithin the lower portion 32B may be defined as the lower volume 34B. Asshown in the illustrated embodiment of FIG. 2, the upper volume 34A andthe lower volume 34B are fluidly separated by the fixed scroll 12 andthe orbiting scroll 14. In an embodiment, gas may only flow between thevolumes 34A, 34B by traveling through the intermeshed scrolls 18, 20(and being compressed) or the gas distributing structure 64 (asexplained below). However, in an embodiment, the volumes 34A, 34B can befluidly separated by, for example, other components of the scrollcompressor 10 or other components and the scrolls 12, 14.

As shown in FIG. 2, the intermeshed spiral wraps 18, 20 in an embodimenthave a discharge volume 40. In a scroll compressor 10, the dischargevolume 40 is a volume where the intermeshed spiral wraps 18, 20 end andthe compressed gas exits the scrolls 12, 14. The discharge volume 40 isfluidly connected to the upper volume 34A of the scroll compressor 10. Avalve 42 (e.g., a check valve) can regulate the flow of pressurized gasbetween the upper volume 34A and the discharge volume 40.

During operation of the scroll compressor 10, the compressed gas flowsout of the scroll compressor 10 by flowing from the discharge volume 40to the upper volume 34A and through the discharge outlet 38. Theintermeshed scrolls 12, 14 also have an inlet 41 where gas flows intothe intermeshed scrolls 12, 14. The inlet 41 is fluidly connected to thelower volume 34B of the scroll compressor 10. Inlet gas (e.g., workingfluid to be compressed by the scroll compressor 10) flows into thescroll compressor 10 through the suction inlet 36. During operation ofthe scroll compressor 10, inlet gas flows into the intermeshed scrolls12, 14 by entering the scroll compressor 10 through the suction inlet36, flowing through the lower volume 34B, and into the inlet 41.

In the illustrated embodiment, pressurized gas flows through the uppervolume 34A to exit the scroll compressor 10. However, in an embodiment,the discharge volume 40 may be directly fluidly connected to thedischarge outlet 38 such that gas exits the scroll compressor 10 byflowing directly from the discharge volume 40 to the discharge outlet38.

As explained above, the orbiting scroll 14 in an embodiment is orbitedby a crankshaft 24. The crankshaft 24 can be rotated by, for example, anelectric motor 44. The electric motor 44 includes a rotor 46 and astator 47. The rotor 46 and the crankshaft 24 are affixed together suchthat they rotate together. For example, the rotor 46 and crankshaft 24can be affixed together using an interference fit or other type of fit.The electric motor 44 may operate using known principles to rotate thecrankshaft 24. In an embodiment, the crankshaft 24 may be rotated byother mechanisms other than an electric motor 44, such as, for example,an external electric motor, an internal combustion engine, or other suchmechanisms. Accordingly, such embodiments may not include the electricmotor 44, rotor 46, and stator 47 as shown in FIG. 2.

In an embodiment, the scroll compressor 10 includes bearings 50, 52, 54that can support crankshaft 24 while still allowing the crankshaft 24 torotate. Radial bearings 50, 52 can support the crankshaft 24 in theradial direction while allowing the crankshaft 24 to rotate. Acrankshaft thrust bearing 54 can support the crankshaft 24 in the axialdirection while still allowing the crankshaft 24 to rotate. In anembodiment, a scroll compressor 10 may include one or more bearings 50,52, 54 to support the crankshaft 24.

As shown in FIG. 2, an end 56 of the crankshaft 24 in an embodiment isan eccentric end 56 relative to the rest of the crankshaft 24. Theeccentric end 56 is eccentric as the axis of the end of the crankshaft24 is radially offset from the rotational axis of the crankshaft 24. Theeccentric end 56 of the crankshaft 24 also includes a bearing 48. Thebearing 48 can prevent the crankshaft 24 from transferring its rotationto the orbiting scroll 14. However, the radial movement of eccentric end56 (e.g., the movement of the eccentric end 56 that is perpendicular tothe axis of rotation) is still transferred to the orbiting scroll 14. Assuch, the orbiting scroll 14 in an embodiment orbits relative to thefixed scroll 12 instead of rotating. In embodiment, the radial bearings48, 50, 52 may be, for example, ball bearings, roller bearings, or thelike.

Thrust bearing 54 supports the crankshaft 24 in the axial directionwhile still allowing the crankshaft 24 to rotate. In an embodiment,thrust bearing 54 is located between an end of the crankshaft 24 (e.g.,an end of the crankshaft 24 that is opposite its eccentric end 56) and asecond fixed supporting member (e.g., lower bearing housing 59).

Lubricant (e.g., oil) can be provided to the bearings 48, 50, 52, 54along the crankshaft 24. In an embodiment, lubricant can be suppliedfrom a lubricant sump 33 that is located in the bottom of the lowervolume 34B of the scroll compressor 10. In an embodiment, the lubricantflows to the bearings 48, 50, 52, 54 by way of an interior gallery 62located within the crankshaft 24. As shown in FIG. 2, the interiorgallery 62 is not parallel with the axis of rotation of the crankshaft24. As the interior gallery 62 is not parallel with an axis of rotationof the crankshaft 24, the centrifugal force of the rotating crankshaft24 can be utilized to suction lubricant from the lubricant sump 33 andinto the bearings 48, 50, 52, 54. However, in an embodiment, theinterior gallery 62 may be parallel with the axis of rotation of thecrankshaft 24.

Alternatively or additionally, scroll compressor 10 may include a pump60 to pump oil from the lubricant sump 33 through the inner gallery 62and into the bearings 48, 50, 52, 54. The illustrated embodimentincludes three radial bearings 48, 50, 52 and a thrust bearing 54 tosupport the crankshaft. However, an embodiment may include one or morebearings 48, 50, 52, 54 in any specific location along the crankshaft24. Bearings may be included as suitable to support the crankshaft 24and allow the orbiting scroll 14 to be rotated and/or orbited correctly,relative to the fixed scroll 12.

As the gas filled volumes (e.g., trapped volume 16, trapped volume 17)are compressed between the spiral wraps 18, 20, the compressed gasexerts a force upon the scrolls 12, 14 in the axial directions. As thefixed scroll 12 cannot be easily moved due to its fixed position withinthe compressor 10, this axial force can push on the orbiting scroll 14in the axial direction as shown by the arrow A in FIG. 2. This effectcan also be referred to as a thrust load. It should be appreciated thatthe thrust load may push on the orbiting scroll 14 along one or morepoints along the baseplate 26 due to the various locations of gas filledvolumes (e.g., trapped volume 16, trapped volume 17). The gas filledvolumes apply a different amount of thrust force as they are beingcompressed to different pressures. The thrust load does not apply anequal amount of force across a radius of the baseplate 26 of theorbiting scroll 14.

If the thrust load is not supported, it can move the orbiting scroll 14in the axial direction from its intermeshed position with the fixedscroll 12. If the orbiting scroll is pushed out of its position, it canalso lead to inadequate sealing between the axial ends of the scrollswraps 18, 20 and the opposing scroll baseplate 26, 13, respectively, inthe axial direction. Inadequate sealing can cause a loss of efficiencyof the scroll compressor 10, or in certain circumstances, the loss ofthe scroll compressor's 10 ability to compress the inlet gas. If thethrust force is not supported, the orbiting scroll 14 could be pushedout of position such that the orbiting scroll 14 contacts and damagesthe fixed supporting member (e.g., the bearing housing 58) that supportsthe crankshaft 24 and/or other internal components of the scrollcompressor 10.

The scroll compressor 10 in an embodiment may include an aerostaticthrust bearing to support (e.g., counteract, dampen) the thrust load.The aerostatic thrust bearing supports the thrust load by supporting theorbiting scroll 14 in the axial direction. In an embodiment, theaerostatic thrust bearing includes the back surface 28 of the orbitingscroll 14, the axial surface 66 of the bearing housing 58, and a gasdistributing structure 64.

In an embodiment, the source of the pressurized gas for the gasdistributing structure 64 is a working fluid of the scroll compressor10. For example, when a scroll compressor 10 is utilized to compress arefrigerant, the compressed refrigerant that is produced by the scrollcompressor 10 may be utilized by the aerostatic thrust bearing tosupport the orbiting scroll 14.

As shown in FIG. 2, the gas distributing structure 64 is located on theaxial surface 66 of the bearing housing 58. In an embodiment, the gasdistributing structure 64 is fluidly connected to the upper volume 34Aby a pathway 68. The pathway 68 allows the pressurized gas within theupper volume 34A to flow to the aerostatic thrust bearings 64.Accordingly, pressurized gas is supplied to the gas distributingstructure 64 from the upper volume 34A.

In the illustrated embodiment of FIG. 2, the pathway 68 is shown asbeing completely within the external housing 22 of the scroll compressor10. However, other embodiments may include a pathway 68 that passesthrough the external housing 22. For example, an embodiment of a scrollcompressor 10 may include a pathway 68 that fluidly connects thedischarge outlet 38 to the gas distributing structure 64 or a pathway 68that provides pressurized gas from an external source instead of the gascompressed by the scroll compressor 10. The illustrated embodiment showsa single pathway 68 from the upper volume 34A to gas distributingstructure 64. However, an embodiment may include one or more pathways 68to the gas distributing structure 64.

As shown in FIG. 2, an optional booster 70 can be utilized to providepressurized gas for the aerostatic thrust bearing. In an embodiment, thebooster 70 is a secondary source of pressurized gas. The booster 70provides pressurized gas when the pressure and/or flowrate of the gasbeing discharged by the scroll compressor 10 is not large enough tosupport the thrust load. For example, the booster 70 can be utilizedduring periods of starting and/or stopping the scroll compressor 10. Inthe illustrated embodiment, the booster 70 is fluidly connected to thepathway 68. However, the booster 70 in an embodiment may, alternativelyor additionally, be fluidly connected to the upper volume 34A or thedischarge outlet 38.

In an embodiment, the booster 70 can be, for example, a vesselcontaining a volume of pressured gas, which has been charged during thenormal operation of the compressor 10. In an embodiment, the booster 70may be a smaller compressor. In embodiments including a booster 70, avalve (e.g. flow control valve 71, a check valve) can be provided in thepathway 68 and/or discharge volume 40 to ensure the pressurized gasflows from the booster 70 to the gas distributing structure 64. Thebooster 70 is shown as being external to the scroll compressor 10.However, in an embodiment, the booster 70 may be located within thescroll compressor 10.

In an embodiment, a flow control device 71 (e.g., flow control valve)may be provided within the pathway 68. The flow control device 71 cancontrol the amount of pressurized gas that flows to the gas distributingstructure 64. Alternatively, the flow control device 71 in an embodimentmay be a structure, such as the narrowing of the pathway 68, thatprovides a pressure drop that regulates the amount of pressurized gasthat flows through the pathway 68.

In the illustrated embodiment, the booster 70 is a secondary source ofpressurized gas. However, in an embodiment, the booster 70 may be aprimary source of pressurized gas. In an embodiment, the booster 70 maybe an external source of pressurized gas that provides all of thepressurized gas for one or more of the aerostatic thrust bearings in acompressor 10. In such an embodiment, the pathway may connect to thebooster 70 instead of the upper volume 34A.

Referring to FIGS. 2 and 3, the gas distributing structure 64 issupplied with pressurized gas from the upper volume 34A by the pathway68. The gas distributing structure 64 distributes the pressurized gasinto a space 43 between the orbiting scroll 14 and the bearing housing58. As shown in FIG. 3, an upper surface 72 of the gas distributingstructure 64 distributes the pressurized gas into the space 43. As theback surface 28 of the orbiting scroll 14 pushes on the fluid flowingthrough the space 43 (due to the thrust force), the distributedpressurized gas is pressed between the axial surface 66 of the bearinghousing 58 and the back surface 28 of the orbiting scroll 14. As such,the flow of distributed pressurized gas forms a layer of pressurized gasbetween the orbiting scroll 14 and the bearing housing 58. This layer ofgas can support the orbiting scroll 14 and its thrust load.

As the orbiting scroll 14 orbits, the thrust load may cause a nutationof the orbiting scroll 14 towards one radial end of the orbiting scroll14. Nutation is the tilting of the orbiting scroll 14 relative to thecrankshaft 24 and/or the bearing housing 58 (e.g., precession). Whennutation occurs, the baseplate 26 is no longer perpendicular tocrankshaft 24. Nutation may occur due to moments applied by compressionand drive forces, as well as the inertia resulting from the orbiting ofthe orbiting scroll 14, and/or the thrust force being unequally appliedacross a diameter of the baseplate 26.

When nutation occurs, a distance (e.g., distance 39 shown in FIG. 3)between the back surface 28 of the orbiting scroll 14 and the axialsurface 66 of the bearing housing 58 is no longer constant around theentire circumference of the orbiting scroll 14 and bearing housing 58.For example, the orbiting scroll 14 is tilted when viewed from ahorizontal direction (e.g., the view shown in FIG. 2) such that itsbaseplate 26 is closer to the bearing housing 58 at one radial end andis farther apart from the bearing housing 58 at an opposite radial end.The nutation/precession would apply an additional force to furthercompress the layer of pressurized gas in areas where the distancebetween the back surface 28 and axial surface 66 is smaller. However,the compression of the layer of flowing pressurized gas causes the layerof flowing pressurized gas to provide a greater force to support theorbiting scroll 14. The layer of pressurized gas providing greatersupport because it provides a larger counter-force to resist furthercompression when the orbiting scroll 14 pushes on the layer ofpressurized gas layer. In an embodiment, the orbiting scroll 14 and thebearing housing 58 are positioned, relative to each other, so that anaxial distance 39 between the back surface 28 and the axial surface 66is small. A smaller distance 39 between the back surface 28 and theaxial surface 66 allows for a relatively smaller flow rate ofpressurized gas to be utilized by the aerostatic thrust bearing toadequately support the orbiting scroll 14 and its thrust load.

In the manner described above, pressurized gas is supplied to the gasdistributing structure 64 such that it can form a layer of pressurizedgas between the orbiting scroll 14 and the bearing housing 58. Theaerostatic thrust bearing utilizes the layer of pressurized gas tosupport the thrust load and prevent the orbiting scroll 14 from beingmoved out of its correct intermeshed position in the axial direction.

In the illustrated embodiment, the gas distributing structure 64 islocated on the bearing housing 58. It should be appreciated that thebearing housing 56 is an example of a fixed supporting member. In anembodiment, the fixed supporting member may be other structures having afixed location (relative to the orbiting scroll 14) and a surface thatfaces the back surface 28 of the orbiting scroll 14.

FIGS. 3A and B show enlarged views of the aerostatic thrust bearingshown in FIG. 2, during the operation of the scroll compressor 10. Asshown in FIG. 3A, the upper surface 72 of the gas distributing structure64 distributes pressurized gas into the space 43. As shown in FIG. 3A,the gas distributing structure 64 is embedded into the axial surface 66of the bearing housing 58. However, the gas distributing structure 64 inan embodiment may protrude from or be entirely above (e.g., located on)the axial surface 66. In an embodiment, the gas distributing structure64 has a thickness 73 and includes an outer side 79 and an inner side81. The illustrated embodiment has a gas distributing structure 64 witha thickness 73 that is uniform in the radial direction (e.g., alongdirections D and E). However, the gas distributing structure 63 in anembodiment may have a thickness 73 that is non-uniform in the radialdirection.

In an embodiment, the gas distributing structure 64 may include one ormore inlets 74. As shown in FIG. 3, the gas distributing structure 64includes an inlet 74 for supplying pressurized gas. The illustratedembodiment shows the back surface 76 of the gas distributing structure64 including the inlet 74. However, an embodiment may include an inlet74, alternatively or additionally, in one or more of the sides 79, 81 ofthe gas distributing structure 64. The illustrated embodiment shows thegas distributing structure 64 having specified inlets 74. Alternatively,a surface or a portion of a surface of the gas distributing structure 64(e.g. a back surface 76, an outer side 79, and inner side 81) may be aninlet surface for the gas distributing structure 64.

Optionally, a groove 78 that travels around all or a portion of thecircumference (shown in FIG. 4) of the aerostatic thrust bearing may beprovided in the gas distributing structure 64. The groove 78 may providea pathway to distribute gas to the gas distributing structure 64. Forexample, the groove 78 may fluidly connect multiple inlets 74 of a gasdistributing structure 64 in an embodiment. In an embodiment, the groove78 may run along an inlet surface of the gas distributing structure 64instead of a specific inlet 74. In such an embodiment, the groove itselfmay form an inlet surface. The pathway 68 may then be fluidly connectedto the groove 78 to supply pressurized gas to the inlet surfaces of thegas distributing structure 64. Alternatively, the groove 78 in anembodiment may be located in the bearing housing 58 along the backsurface 76 of the gas distributing structure 64.

In an embodiment, the gas distributing structure 64 is made of amaterial that allows gas to flow through it in a distributed manner. Forexample, the gas distributing structure 64 may be a porous material. Inan embodiment, the gas distributing structure 64 is a porous carbonsubstrate. In an embodiment, the gas distributing structure 64 has astructure or material that allows the incoming pressurized gas to bedistributed through its upper surface 72 (as shown by the arrows labeledB). As such, the gas distributing structure 64 can equally distributethe inlet gas along its upper surface 72 and into the space 43 betweenthe orbiting scroll 14 and the bearing housing 58. This distribution ofthe gas allows the aerostatic thrust bearing to form a layer ofpressurized gas that can support the thrust load of the orbiting scroll14 in the direction of the arrow C. Once introduced into the space 43between the orbiting scroll 14 and the bearing housing 58, thedistributed pressurized gas flows in direction D and/or direction E.Some of the distributed pressurized gas may also flow in acircumferential direction (e.g., a direction along the circumference ofthe orbiting scroll 14, a direction that would follow the groove 72, adirection perpendicular to directions E, D, and A). However, thedistributed pressurized gas flowing in a circumferential directioneventually exits from between the orbiting scroll 14 and bearing housing58 by traveling along the radial direction (e.g., direction D, directionE).

FIG. 3B is a schematic diagram of the orbiting scroll 14 and the bearinghousing 58 in an embodiment. The sides 79, 81 define the outer radius 84and inner radius 86 (as shown in FIG. 4), respectively, of the gasdistributing structure 64. In an embodiment, the outer edge 85 definesthe outer circumference of the back surface 28 of the orbiting scroll14. If the side 79 is located outside the outer circumference of theback surface 28, the upper surface 72 does not face the back surface 28in an embodiment. This provides a bypass for pressurized gas as it mayflow out of the gas distributing structure 64 without traveling throughthe space 43 between the orbiting scroll 14 and the bearing housing 58(shown in FIG. 3). However, the aerostatic thrust bearing can providegreater support for the outer radius of the back surface 28 when locatedfurther outward (e.g., further towards the outer circumference of theback surface 28). Accordingly, the side 79 of the gas distributingstructure 64 is positioned near, but still within, the outercircumference of the back surface 28. In such a position, the aerostaticthrust bearing provides excellent support for the radial end (e.g., theouter circumference) of the baseplate 28 of the orbiting scroll 14 whilesuitably and/or efficiently utilizing pressurized gas by avoidingby-pass.

Further, the tilting or nutation of the orbiting scroll 14 may befurther suppressed by the side 79 (and the outer radius 84) of the gasdistributing structure 64 being located further outward. It will beappreciated that the gas distributing structure 64 in an embodiment hasa large enough upper surface 72 to support the orbiting scroll 64 in theaxial direction and to prevent the formation of large pressure gradientsas discussed below.

As shown in FIG. 2, the bearing housing 58 and the orbiting scroll 14are located in the lower volume 34B of the scroll compressor 10. Assuch, the space 43 (shown in FIG. 3) is fluidly connected to the lowervolume 34B. In another manner, the space 43 can be defined as a specificportion of the lower volume 34B that is located between the orbitingscroll 14 and the bearing housing 58. The space 43 having a higherpressure relative to the rest of the lower volume 34B due to the flow ofdistributed pressurized gas. Accordingly, the pressurized gasdistributed by the gas distributing structure 64, after being utilizedto support the thrust load, flows from the space 43 in the direction Eor D into the lower volume 34B. As such, the gas utilized by theaerostatic thrust bearing mixes with the inlet gas from the suctioninlet 36, and is recompressed by the scroll compressor 10.

As shown by FIG. 4, the upper surface 72 of the gas distributingstructure 64 in an embodiment has a circular ring shape in a downwardview. FIG. 4 is a downward view of the bearing housing 58 and the uppersurface 72 of the gas distributing structure 64. The bearing housing 58includes a cylindrical through-hole 80 that allows the crankshaft 24 andorbiting scroll 14 to be connected. The circular ring shape allows thegas distributing structure 64 to distribute the supplied pressurized gasalong an area spanning the entire circumference of the back surface 28of the orbiting scroll 14 (shown in FIGS. 2 and 3).

As shown in FIG. 4, the upper surface 72 of the gas distributingstructure 64 has an inner radius 86, an outer radius 84, and radialdistance 82. In an embodiment, the upper surface 72 has a uniform shapearound a circumference of the bearing housing 58. However, the uppersurface 72 in an embodiment may be non-uniform around the circumferenceof bearing housing 58. For example, in an embodiment the radial distance82 of the upper surface 72 and/or a distance between the through-hole 80and the inner radius 86 may be not be constant around the circumferenceof the bearing housing 58.

As shown in FIG. 4, the gas distributing structure 64 includes multipleinlets 74. In an embodiment, one or more pathways 68 (shown in FIGS. 2and 3) may fluidly connect with each inlet 74. In an embodiment, one ormore pathways 68 (shown in FIGS. 2 and 3) may fluidly connect to one ormore grooves (e.g., groove 78) that fluidly connects two or more of theinlets 74. The inlets 74 and groove 78 are shown as dashed lines as theywould not be visible from the view shown in FIG. 4. The illustratedembodiment includes a gas distributing structure with six inlets 74.However, an embodiment may include one or more inlets 74 and/or one ormore inlet surfaces as discussed herein.

As shown in FIG. 4, the groove 78 travels along the entire circumferenceof the gas distributing structure 64. However, in an embodiment, thegroove 78 may travel along only a portion of the circumference of thegas distributing structure 64. In an embodiment, one or more grooves 78may be provided in the gas distributing structure 64 and/or bearinghousing 58. In the illustrated embodiment, the groove 78 only travels ina circumferential direction. However, in an embodiment, the groove 78may travel in a radial direction, a circumferential direction, or adirection that is both circumferential and radial. In an embodiment, thegroove 78 may have multiple portions and each portion may be orientedalong a radial direction, a circumferential direction, or a directionthat is both circumferential and radial. The groove 78 in theillustrated embodiment is aligned with all of the inlets 74. However,the groove 78 in an embodiment may not be perfectly aligned with theinlets 74. The groove 78 in such an embodiment may have one or moreadditional portions (not shown) that connect the groove 78 to the inlets74. The additional portion(s) may travel in along the radial direction,circumferential direction, or a combination of thereof.

The upper surface 72 of the gas distributing structure 64 may have anarea (A). In an embodiment and as described above, the distributedpressurized gas flows from the space 43 into the lower volume 34B. Thelower volume 34B may have a pressure (P_(I)). In an embodiment, thepressure (P_(I)) of the lower volume 34B depends upon the pressure ofthe inlet gas to the scroll compressor 10. The pressurized gas suppliedto the gas distributing structure 64 may have a pressure (P_(p)).Accordingly, in an embodiment, the amount of thrust load (F) that can besupported by aerostatic thrust can be represented as follows:

$P_{P} = {{\left( \frac{F}{A} \right)\left( E_{f} \right)} + P_{I}}$

The aerostatic thrust bearing will also have efficiency (E_(f)). Theefficiency (E_(f)) is an efficiency factor that depends upon a varietyof factors. For example, the factors may include the distance betweenthe orbiting scroll 14 and the bearing housing 58, how equally the gasdistributing structure 64 distributes the incoming pressurized gasacross its entire upper surface 72, the thickness of the gasdistributing structure 64, and the permeability of the material of thegas distributing structure 64.

The efficiency (E_(f)) may be a constant factor or a non-constantfactor. For example, during stable operation, the orbiting scroll 14 mayhave a relatively small amount to no nutation. The efficiency (E_(f))may be constant as the distance between the orbiting scroll 14 and thebearing housing 58 is generally constant. However, the orbiting scroll14 may undergo nutation while operating such that the distance betweenthe orbiting scroll 14 and the bearing housing 58 is non-constant aroundthe circumference of the orbiting scroll 14. This may, for example,cause the efficiency (E_(f)) of the aerostatic bearing to benon-constant.

In an embodiment, a scroll compressor 10 may utilize a constant flow ofinlet gas and compress the inlet gas by a minimum amount (e.g., aminimum compression ratio). Under such circumstances, a minimum pressurefor the pressurized gas (P_(P)) and a maximum pressure of the inlet gas(P_(I)) in an embodiment are known. As such, a gas distributingstructure 64 can be configured to have an area (A) that can support theforce of thrust load (F) at the maximum pressure of the inlet gas(P_(P)) and the minimum pressure of the inlet gas (P_(I)).

In an embodiment, the gas distributing structure 64 may have a ringshape (as shown in FIG. 4) to maximize the surface area (A) of the gasdistributing structure 64. Maximizing the surface area (A) of the gasdistributing structure 64 may be useful, for example, when the thrustload is large and/or the pressure difference between the inlet gas andthe supplied pressurized gas is small due to the inlet gas having amoderate pressure. For example, scroll compressors 10 with a highercompression ratio and/or a large plan area would generally have a largerthrust load.

For example, the pressure of the inlet gas may affect the pressure ofthe lower volume 34A. If the inlet gas is provided at higher pressures,the pressure difference (P_(P)-P_(I)) between the supplied pressurizedgas and the lower volume 34A may be smaller. Accordingly, the gasdistributing structure 64 may have an upper surface 72 with a largersurface area (A) to account for this smaller pressure difference.

An embodiment may partition the lower volume 34B. For example, theaerostatic thrust bearing in an embodiment may be isolated from thelower volume 34B by including one or more dynamic seals that arepositioned between the back surface 28 of the orbiting scroll 14 and theaxial surface 66 of the bearing housing 58. The one or more dynamicseals may direct the flow of the distributed pressurized gas. The lowervolume 34B may have a first portion (not shown) into which thedistributed pressurized gas flows (e.g., the pressurized gas in space 43would flow into a first portion). A second portion (not shown) of thelower volume 34B may be utilized to provide the inlet gas to the inlet41 from the suction inlet 36. The first portion would be fluidlyseparated from the second portion. In such an embodiment, P_(I) in theformula above would be the pressure of the first portion of the lowervolume 34B instead of the pressure based on the inlet gas. In such anembodiment, the inlet gas would no longer be a direct factor of theamount of thrust load (F) the aerostatic thrust bearing may support.

In an embodiment, an aerostatic thrust bearing that includes a gasdistributing structure 64 with smaller surface area (A) may utilize asmaller flow rate of pressurized gas. The pressurized gas utilized bythe aerostatic thrust bearing is gas compressed by the compressor 10 butnot discharged. The energy utilized by the compressor 10 to compress thepressurized gas provided to the aerostatic thrust bearing may beconsidered in some circumstances a system loss. As such, a gasdistributing structure 64 having a smaller surface area (A) does notprovide as large of a system loss for the compressor 10. In anembodiment, a gas distributing structure having a smaller surface area(A) has less impact on the overall efficiency of the compressor 10.

The thrust load does not apply equal amounts of force across a diameterof the baseplate 28 of orbiting scroll 14. In an embodiment, the thrustforce is greater towards the center of the baseplate 28 as gas iscompressed to higher pressures. Referring to FIG. 3B, the thrust forceF₁ is smaller than the thrust force F₂ in an embodiment. A gasdistributing structure 64 that provides adequate support for theorbiting scroll 14 with a small surface area (A) can create largepressure gradients along the back surface 28. For example, the force F₃applied by the distributed pressurized gas may be significantly largerthan the thrust force F₁. The large pressure gradients can cause adeflection of the baseplate 28 and the orbiting scroll 14. Accordingly,the gas distributing structure 64 has a large enough surface area (A) toavoid forming large pressure gradients that may deflect and damage andthe orbiting scroll 14.

As discussed above, the orbiting scroll may undergo nutation. To accountfor this possible nutation and the differing thrust loads across thebaseplate 26, an embodiment of an aerostatic thrust bearing can includea gas distributing structure having separate portions 167 as shown inFIG. 5. In an embodiment, the gas distributing structure may include gasdistributing portions 167 that are located around the circumference of abearing housing 158 as shown in FIG. 5. In an embodiment, each gasdistributing portion 167 may have a shape that corresponds to a segmentof the full ring shaped gas distributing structure 64 shown in FIG. 4.However, an embodiment may have differently shaped gas distributingportions 167 than those shown.

As shown in FIG. 5, each gas distributing portion 167 includes an inlet174. An inlet may be similar to the inlet 74 shown and described forFIGS. 3 and 4. As pressurized gas is separately supplied to each gasdistributing portion 167, the individual gas distributing portions 167are able to separately utilize the pressurized gas. This configurationallows each gas distributing portion 167 to distribute pressurized gaswithout being affected by the manner in which the other gas distributingportions 167 distribute the pressurized gas.

The embodiment shown in FIG. 5 illustrates a gas distributing structurewith gas distributing portions 167. However, a gas distributingstructure in an embodiment may include two or more gas distributingportions 167. An embodiment of gas distributing structure may includefour or more gas distributing portions 167 to account for possiblediffering thrust loads, axial distances 39, and/or local motions aroundthe baseplate 28 (shown in FIG. 2) due to potential nutation of theorbiting scroll 14 (shown in FIG. 2).

For example, the nutation of the orbiting scroll may cause the axialdistance (e.g., axial distance 39 shown in FIG. 3A) between the orbitingscroll 14 and housing 58 to be large at some locations around thecircumference of the orbiting scroll 14. A large axial distance canallow excessive leakage of the high pressurized gas. In an embodiment ofa gas distributing structure 64 without gas distributing portions 176(e.g., the embodiment shown in FIG. 5), excessive leakage may affect theperformance (e.g., reduce the load capacity) of the entire gasdistributing structure 64. In contrast, the gas distributing portions167 are independently supplied with pressurized gas such that excessiveleaking of pressurized gas is less likely to affect or has a minimizedaffect on the performance of the other gas distributing portions 167.

As shown in FIG. 6, a gas distributing structure 264 in an embodimentincludes an upper surface 272 that is sloped relative to the axialsurface 266 of the bearing housing 258. The gas distributing structure264 may include features similar to the gas distributing structure 64shown in FIG. 3, except for the upper surface 272 which has a slope 277.Similar to the gas distributing structures shown in FIGS. 2-5, the gasdistributing structure 264 distributes a pressurized gas between theback surface 228 of the baseplate of the orbiting scroll 214 and theaxial surface 266 of the bearing housing 258. As similarly describedabove for FIGS. 2-5, pressurized gas is supplied to the gas distributingstructure 264 via a pathway 268.

The slope 277 of the upper surface 272 allows the pressurized gas toflow out of the gas distributing structure 264 in a different mannerthan the gas distributing structure 64 shown in FIG. 3. For example, theslope 277 of the upper surface 272 can affect the direction of the gasflowing out of the gas distributing structure 264. As the upper surface272 in an embodiment is oriented in the direction of the arrow F, thegas flowing out of the gas distributing structure 264 flows in thedirection of the arrow F. Further, flow of pressurized gas out of thesloped upper surface 272 can affect the manner in which the pressurizedgas flows outside of the gas distributing structure 264.

Depending upon the internal structure (e.g., permeability) of the gasdistributing structure 264 in an embodiment, the non-constant thickness273 of the gas distributing structure 264 can also affect the flow rateof the gas out of the upper surface 272. For example, the pressurizedgas can flow out of the gas distributing structure 264 at differentrates along its upper surface 272. However, a gas distributing structure64, 164, 264 in an embodiment may not have a constant internal structurethroughout. For example, the gas distributing structure 264 may have anon-constant internal structure to ensure a more even distribution ofthe pressurized gas along the upper surface 272 from a central source ofpressurized gas (e.g. an inlet 274).

Alternatively, a gas distributing structure (e.g., gas distributingstructure 64 shown in FIG. 3) in an embodiment may be embedded into theaxial surface 266 of the bearing housing 258 at an angle. In such anembodiment, the gas distributing structure can have a uniform thickness273 while still having an upper surface 272 that has a slope 277(relative to the axial surface 266).

An embodiment may have a different slope for the upper surface 272 thanthe slope 277 shown in FIG. 6. The slope 277 may be different so as tochange, for example, the direction of the pressurized gas flowing out ofthe gas distributing structure 264, and/or the flowrate of thepressurized gas flowing out of the gas distributing structure 264. Inthe illustrated embodiment, the gas distributing structure 264 isthicker towards an inner side 281. However, in an embodiment, the gasdistributing structure 264 may be thicker towards the outer side 279instead of the inner side 281.

The slope 277 of the upper surface 272 may be configured so as to ensurethat the outer radial end (e.g., the outer circumference) of thebaseplate of the orbiting scroll 214 is adequately supported (e.g. inthe direction of arrow C). The sloped upper surface 277 may support theradial end of the baseplate of the orbiting scroll 214 by directing theflow of the distributed gas. For example, the configuration of the slope277 of the upper surface 272 in an embodiment may provide a largerquantity of pressurized gas in the direction E than the direction D. Insuch an embodiment, the larger flow of gas in the direction of the outerradius of the baseplate of the orbiting scroll 214 (e.g., direction E)may better support the radial end of the baseplate.

In an embodiment, the upper surface 72, 272 of the gas distributingstructure 64, 264 may be sloped in the circumferential direction (e.g.,along circumference of the baseplate 26, along the circumference of thebaseplate of the orbiting scroll 214). In an embodiment, the slope ofthe upper surface 72, 264 in the circumferential direction may benon-constant. For example, the upper surface 72, 272 may include adownward sloped portion and an upward slopped portion so as to formgrooves in the upper surface 72, 272. In an embodiment, these grooves inthe upper surface 27,272 may be formed along a radial direction.

The friction between the back surface 228 and the flowing pressurizedgas can push pressurized gas in the direction of the orbit of theorbiting scroll 14. In an embodiment, the upper surface 272 of the gasdistributing structure 264 may utilize the pressurized gas pushed by theorbiting scroll 14 to form areas of higher relative pressures. Forexample, these areas of high relative pressures may be referred to as apressurized gas wedge. The slope of the upper surface 272 may be in thecircumferential direction and/or radial direction (as shown in FIG. 6)so as to form pressurized gas wedges in specific locations. The slope ofthe upper surface 72, 272 may not be constant as the orbit of theorbiting scroll 14. These area or areas of gas with higher relativepressures may enhance the amount of support provided by the aerostaticthrust bearing.

The gas distributing structures 64, 264 are shown as being entirelybelow the axial surface 66, 266 of the bearing housing 58, 258. However,the gas distributing structure 64, 264 in an embodiment may protrudeabove the axial surface 66 or be entirely above (e.g., located on) theaxial surface 66, 266 of the bearing housing 58, 258.

As shown in FIG. 7, a scroll compressor 310 in an embodiment has anaerostatic thrust bearing that includes a gas distributing structure 364located on a back surface 328 of the orbiting scroll 314. The scrollcompressor 310 also includes a fixed scroll 312 with a spiral wrap 318,similar to the scroll compressor 10 shown in FIG. 2. The orbiting scroll314 also includes a spiral wrap 320. The fixed scroll 312 and orbitingscroll 314 and their respective spiral wraps are intermeshed similar tothe compressor 10 shown in FIG. 2 and described above. A coupling device(e.g., Oldham coupling 30) has been omitted from the view shown in FIG.7 for ease of understanding.

In an embodiment, the aerostatic thrust bearing includes the backsurface 328 of the orbiting scroll 314, an axial surface 366 of thebearing housing 358, and the gas distributing structure 364. The gasdistributing structure 364 of the aerostatic thrust bearing is locatedon the back surface 328 of the baseplate 326 of the orbiting scroll 314.The scroll compressor 310 may have similar features to the scrollcompressor 10 shown in FIG. 2 and described above, except as describedherein. In an embodiment, the gas distributing structure 364 may includefeatures similar to the gas distributing structures 64, 164, 264 shownin FIGS. 2-6. For example, the gas distributing structure 364 may haveseparated portions and/or a sloped upper surface.

In a similar manner to the gas distributing structures 64, 164, 264shown in FIGS. 2-6, the gas distributing structure 364 distributes apressurized gas between the back surface 328 of the orbiting scroll 314and the axial surface 366 of the bearing housing 358. As similarlydescribed above, the distributed pressurized gas then flows into thelower volume 334B of the scroll compressor 310. The flowing distributedpressurized gas is formed into a layer between the orbiting scroll 314and the bearing housing 358 by the surfaces of the aerostatic thrustbearing. The layer supports the orbiting scroll in the axial directionas similarly described above. In this manner, the aerostatic thrustbearing may support the orbiting scroll 314 and its thrust load suchthat the orbiting scroll 314 does not move out of its correctintermeshed position with the fixed scroll 312 in the axial direction.

In an embodiment, the gas distributing structure 364 is supplied with apressurized gas from a discharge volume 340 of the spiral wraps 318,320. The discharge volume 340 shown in FIG. 7 may have a similarconfiguration to the discharge volume 40 described above for FIG. 2,except that the discharge volume 340 also includes a secondary outlet365. A passageway 368 in the baseplate 326 of the orbiting scroll 314fluidly connects the discharge volume 340 to the gas distributingstructure 364 via the secondary outlet 365. In such a manner,pressurized gas is supplied to the aerostatic thrust bearing from thedischarge volume 340 through the baseplate 326 of the orbiting scroll314.

In an embodiment, the inlet (e.g. the secondary outlet 365) for thepassageway 368 can be located at a different radial location of thebaseplate 326. In such an embodiment, the passageway 365 may fluidlyconnect the gas distributing structure 364 to an intermediate volume(e.g., trapped volume 316, trapped volume 317) of the scrolls 312, 314.Accordingly, the discharge volume 340 in such an embodiment may or maynot have the secondary outlet 365.

The inlet for the passageway 368 in an embodiment may be located on theouter radial surface of baseplate 326. In such an embodiment,pressurized gas from an internal source (e.g., upper volume 334A) or anexternal source (e.g. a booster, not shown) could supply the gasdistributing structure 364 with pressurized gas via the outer radialsurface of the baseplate 326 instead of the discharge volume 340.

In an embodiment, the pressure drop across the aerostatic thrust bearingmay control the amount of pressurized gas that flows through theaerostatic thrust bearing. However, the passageway 368 in an embodimentmay include one or more flow control mechanisms (e.g., narrowing of thepassageway 368, a flow control valve (e.g, flow control valve 71) toprevent more than the desired amount of pressurized gas from flowingthrough the aerostatic thrust bearing.

In an embodiment, the passageway 368 can include portions, and eachportion can fluidly connect the passageway 368 to different locationsalong the circumference of the gas distribution structure 364.Alternatively or additionally, the passageway 368 may be fluidlyconnected to a groove (e.g., a groove similar to the groove 78) thatfluidly connects one or more inlets (e.g., similar to inlets 74, 174,274) of the gas distributing structure 364. As similarly describedabove, the gas distributing structure 364 in an embodiment may be acontinuous ring (e.g., gas distributing structure 64) or it may haveseparate sections or portions (e.g., the gas distributing portions 167).In an embodiment, the upper surface of the gas distributing structure364 (e.g. the surface of the gas distributing structure 364 facing thebearing housing 358) may be sloped relative to the back surface 328 ofthe orbiting scroll 314, in a similar manner to the gas distributingstructure 264 in FIG. 6.

During normal operation, the gas distributing structure 364 distributespressurized gas between the bearing housing 358 and the orbiting scroll314. As similarly described above, the distributed pressurized gas flowsfrom between the orbiting scroll 314 and the bearing housing 358 into alower volume 334B of the scroll compressor 310. The distributedpressurized gas is pressed between the axial surface 366 and the backsurface 328 such that it forms a layer of flowing pressurized gasbetween the bearing housing 358 and the orbiting scroll 314. This layerof flowing pressurized gas supports the orbiting scroll 314 in the axialdirection and the thrust load produced by the scrolls 312, 314. In sucha manner, the aerostatic thrust bearing supports the orbiting scroll 314and its thrust load. During normal operation, the aerostatic thrustbearing ensures that the orbiting scroll 314 stays in its correctintermeshed position with the fixed scroll 312 in the axial direction.

In an embodiment, a booster (e.g., booster 70 in FIG. 2) may be includedto supply pressurized gas to the aerostatic thrust bearing. The boostermay be a secondary source of pressurized gas for the aerostatic thrustbearing. The booster may provide pressurized gas, for example, whenthere is inadequate pressurized gas to support the thrust load (e.g.,during the startup of the compressor, during the shutdown of thecompressor). In an embodiment, the booster may be fluidly connected togas distributing structure 364 by way of, for example, the dischargevolume 340, a radial surface of the baseplate 326, an upper volume 334A,and/or the discharge outlet 338.

A scroll compressor in an embodiment may be oil-free scroll compressor400 as shown in FIG. 8. The scroll compressor 400 shown in FIG. 8 is avertical, single-stage, scroll compressor. FIG. 8 is a cross-sectionalview of the oil-free scroll compressor 400. An oil-free scrollcompressor 400 includes aerostatic thrust bearings and aerostatic radialbearings. Pressurized gas is supplied to the aerostatic bearings. In anembodiment, the pressurized gas may be a refrigerant that has beencompressed by the scroll compressor 400. A coupling device (e.g., Oldhamcoupling 30) has been omitted from the view shown in FIG. 11 for ease ofunderstanding. However, in an embodiment, it should be appreciated thatan additional aerostatic bearing or gas distributing structure may beprovided for a coupling device that requires lubrication in anembodiment of an oil-free scroll compressor 400. The gas distributingstructure for the coupling device may be located in the orbiting scroll414 and/or the bearing housing 458.

In an embodiment of an oil-free scroll compressor 400, the orbitingscroll 414 and its thrust load may be supported in the axial directionby an aerostatic thrust bearing. The aerostatic thrust bearing includesa gas distributing structure 464. Similar to the scroll compressor 310shown in FIG. 7 and as described above, the gas distributing structure464 is located on the orbiting scroll 414 and is supplied pressurizedgas from a discharge volume 442 of the scrolls 412, 414 by a passageway468. In an embodiment, a secondary inlet 465 for the passageway 468 maybe located at another radial location of the orbiting scroll 414 assimilarly described above for FIG. 7. In an embodiment, the aerostaticthrust bearing in an embodiment may have the gas distributing structure464 on the axial surface 466 of the bearing housing 458, similarly tothe gas distributing structures 64, 164, 264 shown in FIGS. 2-6.

For example, an electric motor 444 (similar to the electric motor 44described above for FIG. 2) is included in the scroll compressor 400 torotate the crankshaft 424. The scroll compressor 400 includes aerostaticradial bearings for supporting the crankshaft 424 in the radialdirection and a crankshaft aerostatic thrust bearing for supporting thecrankshaft 424 in the axial direction. The scroll compressor 400 alsoincludes an aerostatic radial bearing located between an end of thecrankshaft 424 (e.g. an eccentric end 456) and the orbiting scroll 414.In an embodiment, each aerostatic bearing along the crankshaft includesa gas distributing structure 448, 450, 452, 454 located on thecrankshaft 424.

A first radial bearing and second radial bearing support the crankshaft424 in the radial direction while it rotates. A first aerostatic radialbearing includes a radial surface of the crankshaft 424, a radialsurface of the bearing housing 458 (e.g., a surface of the bearinghousing facing the radial surface of the crankshaft 424), and the gasdistributing structure 450. The first radial bearing is described inmore detail below for FIG. 9. As shown in FIG. 8, a second aerostaticradial bearing includes a radial surface of the crankshaft 424, a radialsurface of a lower bearing housing 459 (e.g. a surface of the lowerbearing housing 459 that faces the radial surface of the crankshaft424), and the gas distributing structure 452.

The crankshaft aerostatic thrust bearing supports the crankshaft 424 inthe axial direction while it rotates. The crankshaft aerostatic thrustbearing is located at an axial surface of an end of the crankshaft 424opposite of the eccentric end 456. The crankshaft aerostatic thrustbearing includes the axial surface of an end of the crankshaft 424, anaxial surface of the lower bearing housing 459, and the gas distributingstructure 454. The crankshaft thrust bearing is described in more detailbelow regarding FIG. 10A.

The scroll compressor 400 also includes the aerostatic radial bearingfor the eccentric end 456 of the crankshaft 424 that engages with theorbiting scroll 414. In an embodiment, the aerostatic radial bearing forthe eccentric end 456, with the coupling device, allows the eccentricend 456 to transfer its radial movement without transferring itsrotation to the orbiting scroll 414. The aerostatic radial bearing forthe eccentric end 456 includes a radial surface of the eccentric end 456of the crankshaft 424, a surface of the orbiting scroll 414 (e.g. asurface of orbiting scroll 414 that faces the radial surface of theeccentric end 456), and the gas distribution structure 448 located onthe surface of the eccentric end 456.

Similar to the scroll compressors 10, 310 shown in FIGS. 2 and 7, alower volume 434B of the scroll compressor 400 is fluidly separated froman upper volume 434A, and an inlet 441 of the intermeshed scroll 412,414 is located in the lower volume 434B. As such, the gas within thelower volume 434B is supplied to the scrolls 412, 414 for compression.Inlet gas is supplied to the lower volume 434B by a suction inlet 436.As shown in FIG. 8, the aerostatic bearings of the scroll compressor 400(and their respective gas distributing structures 448, 450, 452, 454,464) are located in the lower volume 434B of the scroll compressor 400.Accordingly, the pressurized gas distributed by the gas distributingstructures 448, 450, 452, 454, 464 flows into the lower volume 434B andcan mix with the inlet gas in the lower volume 434B. In such a manner,the pressurized gas utilized by the aerostatic bearings is recompressed.As the pressurized gas and the inlet gas are the same type of gas (e.g.,a refrigerant) in an embodiment, the pressurized gas distributed by thegas distributing structures 448, 450, 452, 454, 464 does not have to beseparated from the inlet gas. As discussed above, in an embodiment, thelower volume 334B may be partitioned such that the gas utilized by theaerostatic bearings and the inlet gas do not mix.

As shown in FIG. 8, the crankshaft 424 has interior gallery 462 thattravels through most of the length of the crankshaft 424. The gasdistributing structures 448, 450, 452, 454 located along the crankshaft424 are fluidly connected to the interior gallery 462 of the crankshaft424. In an embodiment, a connecting passageway 469 fluidly connects theinterior gallery 462 to the upper volume 434A of the scroll compressor400. As similarly described above for FIGS. 2-7, the upper volume 434Ain an embodiment is fluidly connected to the discharge volume 440 of thescrolls 412, 414. Accordingly, the pressurized gas supplied to the gasdistributing structures 448, 450, 452, 454 along the crankshaft 424 isthe gas compressed by the scroll compressor 400.

In the embodiment illustrated in FIG. 8, the connecting passageway 469is entirely within the external housing 422 of the scroll compressor400. However, an embodiment may have a connecting passageway 469 thatpasses through the external housing 422. In such embodiments, a sourceof pressurized gas for the aerostatic bearings on the crankshaft 424 maybe an external source (e.g., a separate compressor, a booster), or thedischarge outlet 438 of the scroll compressor 400. In an embodiment, theconnecting passageway 469 may include a flow control device (e.g., theflow control device 71 shown in FIG. 2) to control and/or stop the flowof gas to the gas distributing structures 448, 450, 452, 454.

In an embodiment, the scroll compressor may be a multi-stage scrollcompressor that has orbiting scrolls 414 located on both ends of thecrankshaft 424. In such an embodiment, the connecting passageway 469 maybe fluidly connected to the interior gallery 462, for example, through aradial surface of the crankshaft 424 instead of the end of thecrankshaft 424. Additionally, a scroll compressor may include a booster(e.g., booster 70) as described herein. The booster may be external orinternal to the scroll compressor 400 in an embodiment. In anembodiment, the booster may be a primary source of pressurized gas asdescribed above. Further, the booster in an embodiment may be a primarysource of pressurized gas for one or more of the aerostatic bearings inthe oil-free scroll compressor 400.

FIG. 9 is a partial cross-sectional view of one of the aerostatic radialbearings of the scroll compressor 400 from the line 9-9 shown in FIG. 8.The aerostatic radial bearing includes the outer surface 451 of thecrankshaft 424, the radial surface 463 of the bearing housing 458, andthe gas distributing structure 450.

As shown in FIG. 9, the gas distributing structure 450 forms the entireouter surface 451 of the crankshaft 424 near the bearing housing 458. Assuch, the crankshaft 424 and the gas distributing structure 450 have thesame outer surface 451. However, the gas distributing structure 450 inan embodiment may not form the entire outer surface of the crankshaft424. For example, the gas distributing structure 450 in an embodiment,when viewed in an axial direction (e.g., the view shown in FIG. 9), mayhave portions along the circumference of the crankshaft 424 (e.g. alongthe direction G), and the portions of the gas distributing structure 450may not contact each other. In an embodiment, the gas distributingstructure 450 may have multiple portions along the axial direction ofthe crankshaft 424, along the circumference of the crankshaft 424, orboth.

As shown in FIG. 9, pathways 429 fluidly connect the interior gallery462 of the crankshaft 424 to the gas distributing structure 450. Assuch, pressurized gas is supplied to the aerostatic radial bearing fromthe internal gallery 462. During normal operation of the scrollcompressor 400, the gas distributing structure 450 distributes thesupplied pressurized gas along its outer surface 451. The distributedpressurized gas is then pressed between the surfaces of the aerostaticradial bearing such that a layer of flowing pressurized gas is formed inthe space 461 between the crankshaft 424 and the bearing housing 458. Inan embodiment, this layer of flowing pressurized gas supports thecrankshaft 424 as it rotates, which prevents the crankshaft 424 fromcontacting the bearing housing 458 as the crankshaft 424 is rotated.

In the illustrated embodiment, the crankshaft 424 has two pathways 429.However, an embodiment may include one or more pathways 429 as may besuitable to adequately supply pressurized gas to the gas distributingstructure 450 such that the aerostatic radial bearing can support thecrankshaft 424 as it rotates. In embodiments with a gas distributingstructure 450 having multiple portions (not shown), a pathway 429 may beprovided for each portion.

The crankshaft 424 and/or the aerostatic radial bearing 450 may includeone or more grooves (not shown) in its surface. In an embodiment, theone or more groove or grooves may be located along the radial surfaceand through an interior part 427 of the crankshaft 424 that faces theinner radial surface of the aerostatic radial bearing. A groove orgrooves may travel along the axial direction of the crankshaft 424,circumferential direction of the crankshaft 424 (e.g. along thedirection G), or both. As similarly discuss above regarding the gasdistributing structure 64, 164, 264 in FIGS. 2-6, the gas distributingstructure 450 may have one or more inlets 421 or inlet surfaces. Agroove may allow pressurized gas to be supplied to the one or moreinlets 421 or inlet surfaces of the gas distributing structure 450without requiring additional pathways 429. In embodiments of gasdistributing structure 450 having multiple portions (not shown), agroove may fluidly connect two or more of the inlet(s) 421 and/or inletsurface(s) of each portion.

In the illustrated embodiment, the gas distributing structure 450 has auniform thickness 449. However, a gas distributing structure 450 in anembodiment may have a non-uniform thickness 449. In an embodiment, theother aerostatic radial bearings along the crankshaft, which may includeeach include a gas distributing structure 448, 452, may have a structuresimilar to the first aerostatic radial bearing shown in FIG. 9. In anembodiment, other aerostatic radial bearings may include a differentsurface that faces that radial surface of the crankshaft (e.g., axialsurface of the lower bearing housing 459, a surface of the orbitingscroll 414).

An enlarged, partial view of the crankshaft aerostatic thrust bearing ofthe oil-free scroll compressor 400 of FIG. 9 during its normal operationis shown in FIG. 10A. The crankshaft aerostatic thrust bearing includesan axial surface 491 of the crankshaft 424, an axial surface 492 of thelower bearing housing 459, and a gas distributing structure 454. In anembodiment, two pathways 493 in the crankshaft 424 fluidly connect thegas distributing structure 454 to the interior gallery 462. As shown inFIG. 8, the pathway 469 in an embodiment fluidly connects the uppervolume 434A of the scroll compressor 400 to the interior gallery 462. Assuch, the gas distributing structure 454 is fluidly connected to uppervolume 434A of the scroll compressor 400.

During operation of the scroll compressor 400, pressurized gas from theupper volume 334A is supplied to the gas distributing structure 454. Assimilarly described above, the gas distributing structure 454 has aconfiguration and/or composition (e.g., material properties, internalconfiguration) such that it distributes the supplied pressurized gasalong its outer surface 455. Accordingly, the gas distributing structure454 more equally distributes the supplied pressurized gas into the space495 between the axial surface 491 of the crankshaft 424 and the axialsurface 492 of the lower bearing housing 459. The distribution ofpressurized gas allows the crankshaft aerostatic thrust bearing to forma layer of flowing pressurized gas in the space 495. This layer offlowing pressurized gas supports the crankshaft 424 in the axialdirection as it rotates.

As shown in FIG. 10A, a dynamic seal 494A is provided between the axialsurface 491 of the crankshaft 424 and the axial surface 492 of thebearing housing 459. The dynamic seal 494A can direct the pressurizedgas flowing from the pathway 469 into the internal gallery 462. Thedynamic seal 494A in an embodiment prevents the pressurized gas providedby the passageway 469 from bypassing the interior gallery 462. Thedynamic seal 494A can be made of a material that allows it easily tocontract and expand. This allows the dynamic seal 494A to provide a sealbetween the axial surfaces 491, 492 even if the crankshaft 424 and lowerbearing housing 459 shift relative to each other in the axial direction.

As shown in FIG. 10B, a radial dynamic seal 494B may be provided in anembodiment instead of or in addition to the axial dynamic seal 494A. Arigid member 496 such as a tube may be provided with the radial dynamicseal 494B. The rigid member 496 fluidly connects the connectingpassageway 469 and the internal gallery 462 in an embodiment. An end 497of the rigid member 496 is press fit into the bore forming the interiorgallery 462. The end 497 is fit into the interior gallery 462 such thatthe rigid member 496 is in a fixed position relative to the crankshaft424. Accordingly, the rigid member 496 rotates with the crankshaft 424.The radial dynamic seal 494B is positioned around the connectingpassageway 469. The radial dynamic seal 494B forms a last portion of theconnecting passageway 469 in an embodiment. The opposite end 498 of therigid tube 494 is fit into the radial dynamic seal 494B. The radialdynamic seal 494B provides a seal between the lower bearing housing 459and an outer radial surface of the opposite end 498 of the rigid member496. The radial dynamic seal 494B provides sealing such that thepressurized gas flowing through the connecting passageway 469 flowsthrough the rigid member and into the interior gallery 462. As shown inFIG. 10B, the radial dynamic seal 494B may also include a spring 499.The spring 499 may bias the radial dynamic seal 494B against the outersurface of the rigid member 496 to improve sealing.

In the illustrated embodiment, the crankshaft 424 includes two pathways493 for the gas distributing structure 454 to distribute pressurized gasinto the space 495. However, the crankshaft 424 in an embodiment mayinclude one or more pathways 493 for supplying pressurized fluid to thegas distributing structure 454. It should be understood that the gasdistributing structure 454 may have a features similar to the gasdistributing structures 64, 164, 264 discussed above in FIGS. 3-6. Forexample, the gas distributing structure 454 may have separate portionsand/or a sloped outer surface 455 relative to the axial surface 491 ofthe crankshaft 424. As shown in FIG. 10A, the gas distributing structure454 is embedded into the crankshaft 424 such that the outer surface 455of the gas distributing structure 454 and the axial surface 491 of thecrankshaft 424 form a flat surface. However, the gas distributingstructure 454 in an embodiment may protrude from the axial surface 491.In an embodiment, the entirety of the gas distributing structure 454 maybe above the axial surface 491.

A cross-sectional view of a vertical, oil-free scroll compressor 500 isshown in FIG. 11. The scroll compressor 500 may have similar features tothe scroll compressor 400 shown in FIGS. 8-10 and described above,except as described herein. The scroll compressor 500 includes radialaerostatic bearings to support the crankshaft 524 as it rotates. Thescroll compressor 500 also includes an aerostatic thrust bearing thatsupports the orbiting scroll 514 in the axial direction as it orbits.The scroll compressor 500 also includes an aerostatic radial bearing onthe eccentric end 556 of the crankshaft 524.

Each of the aerostatic bearings along the crankshaft includes arespective gas distributing structure 548, 550, 552, 554. As similarlydiscussed regarding FIG. 7, the scroll compressor 500 includes anaerostatic thrust bearing to support the orbiting scroll 514 in theaxial direction. The aerostatic thrust bearing includes a gasdistributing structure 564 that is located on the orbiting scroll 514.The gas distributing structure 564 in an embodiment may be located onthe surface of the bearing housing 558, as similarly discussed aboveregarding FIGS. 2-6. A coupling device (e.g., Oldham coupling 30) hasbeen omitted from the view shown in FIG. 11 for ease of understanding.

A first radial bearing for supporting the crankshaft 524 includes a gasdistributing structure 550 that is located on the radial surface of thebearing housing 558. A second radial bearing for supporting thecrankshaft 524 includes a gas distributing structure 552 that is locatedon a radial surface of a lower bearing housing 559. The radial surfaceof the lower bearing housing 559 is a surface of the lower bearinghousing 559 that faces the radial surface of the crankshaft 524. Acrankshaft aerostatic thrust bearing for supporting the crankshaft 524in the axial direction as it rotates includes a gas distributingstructure 554 that is located on an axial surface of the lower bearinghousing 559. The axial surface 554 is a surface of the lower bearinghousing 559 that faces an end of the crankshaft 524.

A passageway 569 fluidly connects the gas distributing structures 550,552, 554 in the bearing housing 558 and lower bearing housing 559 to anupper volume 534A of the scroll compressor 500. Accordingly, pressurizedgas is supplied from the upper volume 534A to the aerostatic bearingsthat support the crankshaft 524. Alternatively, the connecting pathway569 in an embodiment may fluidly connect the gas distributing structures550, 552, 554 for supporting the crankshaft 524 to an external source ofpressurized gas (e.g. booster, compressor, or the like).

The orbiting scroll 514 includes pathways 565, 568 that fluidly connecta discharge volume 540 of the intermeshed fixed scroll 512 and orbitingscroll 514 to the gas distributing structures 548, 564 located onsurfaces of the orbiting scroll 514. The pathway 568 providespressurized gas from the discharge volume 540 to the aerostatic thrustbearings supporting the orbiting scroll 514 in the axial direction. Thepathway 565 provides pressurized gas to the aerostatic radial bearingfor the eccentric end 556 of crankshaft 524. In an embodiment, an inlet541 for one or both of the passageways 565, 568 in an embodiment may belocated at a different radial position such that pressurized gas isprovided from an intermediately formed volume (e.g., trapped volume 516,trapped volume 517) instead of the discharge volume 640.

As discussed above, a booster (e.g., booster 70 shown in FIG. 2) may beutilized to provide a secondary source of pressurized gas for one ormore of the aerostatic bearing. In an embodiment, a booster may be aprimary source of pressurized gas that provides all of the pressurizedgas to the aerostatic bearings. In an embodiment, a booster may be aprimary source of pressurized gas for one or more of the aerostaticbearings.

One aspect of the distributing structures 550, 552 being located inbearing housing 558 and lower bearing housing 559 is that they do notrotate with the crankshaft 546. The gas distributing structures 550, 552would not be under a centrifugal force as they are not rotated. This maybe advantageous as the gas distributing structures 550, 552 may not haveto be as strongly attached to the bearing housing 558 and lower bearinghousing 559, respectively, to account for a centrifugal force.

If the gas distributing structures are affixed to a rotating member(e.g., the crankshaft 524), the flow of pressured gas through and out ofthe gas distributing structures may be affected by the centrifugalforces caused by their rotation. In an embodiment, the gas distributingstructures may be designed to counteract possible flow issues caused bythe centrifugal forces. However, the gas distributing structures 550,552 may be advantageous in that they do not have to account forcentrifugal forces because they are located in the bearing housing 558and lower bearing housing 559.

This can be advantageous, for example, in a horizontal scrollcompressor. In an embodiment of a horizontal scroll compressor, the gasdistributing structures 550, 552 can have a configuration (e.g.,internal and/or external structure, material properties) such that theouter surface of the gas distributing structure has a greater flow ratein the upward direction (e.g., the direction opposite the direction ofgravity, the vertical upward direction). In an embodiment of ahorizontal scroll compressor, the radial bearings may be configured toaccount for (e.g., counter) the weight of the crankshaft 524. The largerflowrate of gas in the upward direction can account for the weight ofthe crankshaft 524. As such, in an embodiment of a horizontal scrollcompressor, the aerostatic radial bearing or bearings along thecrankshaft 524 may provide greater support for the bottom of thecrankshaft 524 to counter the weight of the crankshaft 524, even thoughthe bottom surface is not constant due to the rotation of the crankshaft524.

In an embodiment of an oil-free scroll compressor 600, pressurized gasis supplied to the aerostatic bearings that support the crankshaft 624via the orbiting scroll 614. The scroll compressor 600 is a vertical,single stage scroll compressor. FIG. 12 is a cross sectional view of thescroll compressor 600. A coupling device (e.g., Oldham coupling 30) hasbeen omitted from view shown in FIG. 12 for ease of understanding. Thescroll compressor 600 may have similar features to the scroll compressor400 shown in FIGS. 8-10 and described above, except as shown anddescribed herein.

In an embodiment of a scroll compressor 600, the baseplate 626 of theorbiting scroll 614 may include a pathway 627 that fluidly connects adischarge volume 640 of the intermeshing scrolls 612, 614 to a clearancevolume 625. The clearance volume 625 is a volume located between an endof the crankshaft 624 (e.g. an end of the eccentric end 656) and thebaseplate 626 of the orbiting scroll 614. The interior gallery 662 isalso fluidly connected to the gas distributing structures 650, 652, 654of the aerostatic bearings that support the crankshaft 624. As such,pressurized gas is supplied to the gas distributing structures 650, 652,654 from the gas discharge volume 640 by way of the passageway 627 inthe baseplate 628.

In an embodiment, a dynamic seal 690 is provided between an eccentricend 656 of the crankshaft 624 and the baseplate 628 of the orbitingscroll 614. The dynamic seal 690 may provide a seal between an axialsurface of the eccentric end 656 of the crankshaft 624 and the axialsurface of the baseplate 628. The dynamic seal 690 ensures that thepressurized gas flows from the passageway 627 to the interior gallery662. During operation, the orbiting scroll 614 may shift relative to thecrankshaft 624 in the axial direction. This shifting may be smallbecause the scroll compressor 600 includes an aerostatic thrust bearingfor supporting the orbiting scroll 614 in the axial direction. However,the dynamic seal 690 is made of a material that allows it to expand andcontract to account for the possible axial shifting. As such, thedynamic seal 690 provides sealing between the baseplate 626 and thecrankshaft 624 even if the axial distance between the crankshaft 624 andbaseplate 626 changes.

Alternatively, in an embodiment the dynamic seal 690 may be a radialseal instead of an axial seal. The radial dynamic seal (not shown) in anembodiment may be located between a radial outer surface of theeccentric end 656 of the crankshaft 624 and the surface of the orbitingscroll 614 that faces the radial outer surface of the eccentric end 656.In such an embodiment, the radial dynamic seal would be located betweenthe gas distributing structure 650 and the clearance volume 625. In anembodiment, the pathway 627 through the baseplate 626 and the interiorgallery 662 may be fluidly connected by a rigid member (e.g. a tube) anda radial dynamic seal in a similar manner to the interior gallery 462and connecting pathway 469 as described for FIG. 10B.

As shown in FIG. 12, the scroll compressor 600 also includes anaerostatic thrust bearing that supports the orbiting scroll 614 in theaxial direction. In an embodiment, the aerostatic thrust bearing may besimilar to the aerostatic thrust bearing shown and described above forFIG. 7. The orbiting scroll 614 also includes a gas distributingstructure 648 for the aerostatic radial bearing for the eccentric end656 of the crankshaft 624. In an embodiment, the aerostatic radialbearing for the eccentric end 656 may be similar to aerostatic radialbearing for the eccentric end 565 shown and described for FIG. 11. Asshown in FIG. 12, two pathways 665, 668 fluidly connect the gasdistributing structures 648, 664 located on the orbiting scroll 614 tothe pathway 627 through the baseplate 626. In the illustratedembodiment, the pathways 665, 668 are shown as being fluidly connectedto each other. However, the pathways 665, 668 in an embodiment may beseparate such that each pathway 665, 668 separately supplies pressurizedfluid from the pathway 627 through the baseplate 626 to its respectivegas distributing structure 648, 664. In an embodiment, each pathway 665,668 may include multiple pathways such that each pathway 665, 668includes multiple pathways that separately supply pressurized gas to arespective gas distributing structure 648, 664. Accordingly, pressurizedfluid from the discharge volume 640 is supplied to the aerostaticbearings located on the orbiting scroll 614.

Alternatively, an inlet 641 to the passageway 627 in an embodiment maybe located at a different radial position such that pressurized gas isprovided from an intermediately formed volume (e.g., trapped volume 616,trapped volume 617) instead of the discharge volume 640. In theillustrated embodiment, the gas distributing structure 648 for theeccentric end 656 of the crankshaft 624 is on the surface of theorbiting scroll 614. Alternatively, the gas distributing structure 648in an embodiment may be located on a radial surface of the eccentric endof the crankshaft 624 as shown in FIG. 8.

In the manner described above, pressurized gas is supplied to the gasdistributing structures 648, 650, 652, 654, 664 from the dischargevolume 640. Accordingly, the gas distributing structure 648 distributespressurized gas such that a layer of flowing pressurized gas is formedbetween a radial surface of the eccentric end 656 of the crankshaft 624and a surface of the orbiting scroll 614.

The first and second aerostatic radial bearings can support thecrankshaft 624 in the radial direction as it rotates. A gas distributingstructure 650 of the first aerostatic radial bearing distributespressurized gas such that a layer of flowing pressurized gas is formedbetween a radial surface of the bearing housing 658 and a radial surfaceof the crankshaft 624. This layer of flowing pressurized gas supportsthe crankshaft 624 in the radial direction.

A gas distributing structure 652 of the second aerostatic radial bearingdistributes pressurized gas such that a layer of flowing pressurized gasis formed between a radial surface of the crankshaft 624 and a radialsurface of a lower bearing housing 659. This layer of flowingpressurized gas supports the crankshaft 624 in the radial direction.

The crankshaft aerostatic thrust bearing can support the crankshaft 624in the axial direction as the crankshaft 624 rotates. A gas distributingstructure 654 of the crankshaft aerostatic thrust bearing distributespressurized gas such that a layer of flowing pressurized gas is formedbetween an axial surface of an end of the crankshaft 624 and an axialsurface of the lower bearing housing 659. This layer of pressurized gassupports the crankshaft 624 in the axial direction.

A gas distributing structure 664 of the aerostatic thrust bearingdistributes pressurized gas such that a layer of flowing pressurized gasis formed between the back surface 626 of the orbiting scroll 614 andaxial surface 666 of the bearing housing 658. The aerostatic thrustbearing can support the orbiting scroll 614 and its thrust force in theaxial direction. The aerostatic thrust bearing supports the orbitingscroll 614 in the axial direction such that the thrust force does notpush the orbiting scroll 614 out of its correct intermeshed positionwith the fixed scroll 612 and/or does not push the orbiting scroll 614such that it contacts the bearing housing 658.

As previously discussed, a scroll compressor 600 may include a booster(e.g., the booster 70 shown in FIG. 1). In an embodiment, the boostercan be fluidly connected to, for example, any of the various pathways(e.g., interior pathway 665, interior gallery 662, pathway 668) orvolumes (e.g., discharge volume 640, upper volume 334A) that supplypressurized gas to one or more of the aerostatic bearings.

It should be understood that while the Figures show the gas distributingstructures in FIGS. 2-12 as being embedded into the surface of aparticular component (e.g., orbiting scroll, bearing housing,crankshaft, lower bearing housing), any of gas distributing structuresdescribed herein with respect to FIGS. 2-12 may be attached to an outersurface of the described component in an embodiment. In suchembodiments, and the space between opposing surfaces may be configuredto allow for such a configuration of the aerostatic bearing or bearings.

FIG. 13 shows a cross section of an embodiment of a scroll compressor700 having an aerostatic thrust bearing for supporting an orbitingscroll member 714. In an embodiment, the aerostatic thrust bearingincludes a gas distributing structure with an opening 764 located in theback surface 728 of the orbiting scroll 714, an inner radial seal 1710,and an outer radial seal 1720. The scroll compressor 700 also includes afixed scroll 712 with a spiral wrap 718. The orbiting scroll 714includes a baseplate 726 and a spiral wrap 720 that projects from thebaseplate 726 in a direction towards the fixed scroll 712. The fixedscroll 712 and orbiting scroll 714 and their respective wraps 718, 720are intermeshed and are configured to compress gas (e.g., refrigerant)in a similar manner to the scroll compressor 10 shown in FIG. 2 and asdescribed above. A coupling device (e.g., an Oldham coupling 30 as shownin FIG. 2) has been omitted from the view shown in FIG. 13 for ease ofunderstanding.

The scroll compressor 700 in an embodiment includes an external housing722 that has an upper portion 732A containing an upper volume 734A and alower portion 732B containing a lower volume 734B similar to thecompressor 10 shown in FIG. 2 and as described above. Gas in the lowervolume 734B is suctioned into and compressed by intermeshed scrolls 712,714, and then the compressed gas is discharged into the upper volume734A from a discharge volume 740 of the scrolls 712, 714. Gas to becompressed enters the external housing 722 through a suction inlet 736and compressed gas exits the external housing 722 through a dischargeoutlet 738.

The orbiting scroll 714 in an embodiment is orbited in a similar mannerto the orbiting scroll 14 in the compressor 10 shown in FIG. 2 and asdescribed above. The orbiting scroll 714 is attached to an eccentric end756 of a crankshaft 724, and the crankshaft 724 is rotated by, forexample, an electric motor 744. The electric motor 744 in an embodimenthas a similar configuration to the electric motor 44 in FIG. 2 and asdescribed above. For example, in an embodiment, the crankshaft 724 maybe rotated by mechanisms other than an electric motor 744, such as, anexternal electric motor, an internal combustion engine, or other suchmechanisms.

As shown in FIG. 13, the compressor 700 includes radial bearings 750,752, and a thrust bearing 754 to support the crankshaft 724 while itrotates. The compressor 700 also includes a radial bearing 748positioned on the eccentric end 756 of the crankshaft 724 to preventrotational movement from being transferred to the orbiting scroll 714.Lubricant (e.g., oil) can be provided to the bearings 748, 750, 752, 754along the crankshaft 724. In an embodiment, lubricant is provided to thebearings 748, 750, 752, 754 from a sump 733 by way of the interiorgallery 762 in a similar manner as described regarding the compressor 10in FIG. 2. The illustrated embodiment includes three radial bearings748, 750, 752 and a thrust bearing 754 along the crankshaft 724.However, an embodiment may include one or more bearings as suitable tosupport the crankshaft 724 and allow the orbiting scroll 714 to berotated and/or orbited correctly, relative to the fixed scroll 712.

As shown in FIGS. 13 and 14, the aerostatic thrust bearing in anembodiment includes a back surface 728 of the orbiting scroll 714, asurface 766 of a bearing support member 758 that faces the back surface728 of the orbiting scroll 714, and a gas distributing structureincluding an opening 764, an outer radial seal 1720, and an inner radialseal 1710. FIG. 14 is an enlarged view of the aerostatic thrust bearingof FIG. 13 in an embodiment. A pathway 768 in the orbiting scroll 714fluidly connects an intermediate volume 717 of the scrolls 712, 714 tothe opening 764 in the back surface 728 of the orbiting scroll 714. Thepathway 768 has an opening 765 that is along the intermediate volume 717of the scrolls 712, 714 in an embodiment. The pathway 768 allowscompressed gas from the intermediate volume 717 to flow to the gasdistributing structure.

The gas distributing structure in FIGS. 13 and 14 includes two openings764, and the orbiting scroll 714 includes two pathways 768. For example,FIG. 14 shows a single opening 764 of the gas distributing structure. Inan embodiment, the gas distributing structure may include one or moreopenings 764 in the back surface 728 of the orbiting scroll 714. In anembodiment, the gas distributing structure may include two or moreopenings 764 in the back surface 728 of the orbiting scroll 714. Forexample, the gas distributing structure in an embodiment may includefive openings 764 in the back surface 728 of the orbiting scroll 714located in similar positions to the inlets 174 shown in FIG. 5. In anembodiment, an orbiting scroll 714 may include a pathway 768 for eachopening 754 (e.g., as shown in FIG. 13 for two openings 764). In anembodiment having multiple openings 764, an orbiting scroll 714 mayinclude one or more pathways 786, and at least one of the pathways 786may be fluidly connected to multiple openings 764 of the gasdistributing structure.

During operation of the compressor 700, the intermediate volume 717 hasa higher pressure than the lower volume 734B of the compressor. As shownin FIG. 13, the aerostatic thrust bearing is located in the lower volume734B of the compressor 700. Accordingly, compressed gas flows from theintermediate volume 717 to a space 743 between the back surface 728 ofthe orbiting scroll 714 and the surface 766 of the bearing supportmember 758, then flows from the space 743 to the lower volume 734B ofthe compressor 700. Compressed gas is discharged from the opening 764 asshown by arrows B₂ in FIG. 14, and then flows radially outward (e.g., indirection E₂) or radially inward (e.g., in direction D₂). As gas flowsthrough the space 743, the thrust load of the orbiting scroll 714squeezes the flowing compressed gas between the back surface 728 of theorbiting scroll 714 and the surface 766 of the bearing support member758. Accordingly, a layer of compressed gas is formed between the backsurface 728 of the orbiting scroll 714 and the surface 766 of thebearing support member 758 as flows through the space 743. The layer ofcompressed gas formed by the aerostatic thrust bearing provides supportin the direction C₂ to support the thrust load of the orbiting scroll714.

The gas distributing structure in an embodiment also includes an innerradial seal 1710 and an outer radial seal 1720. The radial seals 1710,1720 are located between the orbiting scroll 714 and the bearing supportmember 715 in an embodiment. Each of radial seals 1710, 1720 extendsalong the circumference of the back surface 728 of orbiting scroll 714.In an embodiment, each of the radial seals 1710, 1720 is ring shaped.The inner radial seal 1710 is located radially inward of the opening 764and the outer radial seal 1720 is radially outward of the opening 764.In an embodiment, the inner radial seal 1710 may extend near the outerradius of the baseplate 726 of the orbiting scroll 714. The radial seals1710, 1720 are embedded in the surface 766 of the bearing supportstructure 758. However, one or both of the radial seals 1710, 1720, maybe provided on the surface of the 766 of the bearing support structure758 without being embedded in an embodiment. In an embodiment, one orboth of the radial seals 1710, 1720, may be provided on the back surface728 of the orbiting scroll 714.

As shown in FIG. 14, the inner radial seal 1710 has a thickness 1712(e.g., a dimension in the axial direction) and the outer radial seal1720 has a thickness 1722 that results in the radial seals 1710, 1720extending into the space 743. The inner radial seal 1710 creates arestriction 1714 for the compressed gas flowing radially inwardly (e.g.,in direction D₂) and the outer radial seal 1720 forms a restriction 1724for the compressed gas flowing radially outward (e.g., in direction E₂).Each of the restrictions 1714, 1724 has a length in the axial directionthat is shorter than a length 739 of the space 743 in the axialdirection. The radial seals 1710, 1720 in an embodiment allow a layer ofpressurized gas to be formed between the radial seals 1710, 1720 in theradial direction, while also limiting the flow of compressed gas frombetween the portion of the space 743 between the radial seals 1710, 1720in the radial direction. The radial seals 1710, 1720 in an embodimentare advantageous as they limit the amount of pressurized gas that needsto be provided to the space 743 to form a layer of pressured gas thatadequately supports the orbiting scroll 714 in the radial direction.

As the restrictions 1714, 1724 have a length in the axial direction thatis smaller than length 739 in the axial direction of the space 743,compressed gas is forced to compress more as it flows in the radialdirection (e.g., in direction E₂ or direction D₂) through therestrictions 1714, 1724. Additionally, the orbit of the orbiting scroll714 can cause the pressured gas in the space 743 to flow in an outwardradial direction due to friction. As the compressed gas is forced in theradial outward direction, it is forced through the restrictions 1714,1724 and is further compressed. As such, in addition to the aerostaticsupport provided by the aerostatic thrust bearing of FIGS. 13 and 14,the aerostatic thrust bearing may also provide portions of furthercompressed gas in the restrictions 1714, 1724 that provide aerodynamicsupport to the orbiting scroll 714. In such an embodiment, theaerostatic thrust bearing may also be referred to as a hybridaerostatic/aerodynamic thrust bearing.

In an embodiment, the radial seals 1710, 1720, the pathway 768, and theopening 764 are configured so that the aerostatic thrust providesadequate support for the orbiting scroll 714 in the axial directionwhile limiting the amount of compressed gas needed to provide saidadequate support. The radial seals 1710, 1720 in an embodiment may beconfigured to have a specific length 1712, 1722 so as to provide adesired length in the axial direction for the restrictions 1714, 1724.For example, it may be desired in an embodiment that the length of therestrictions 1714, 1724 in the axial direction are small so as tominimize the flow of compressed gas from the space 743. The pathway 768in an embodiment may be configured to connect to a different volume ofthe intermeshed scrolls (e.g., intermediate volume 716, discharge volume740) or to have a different size (e.g., cross-sectional area) to controlamount of gas that flow one of the more of the openings 764 of the gasdistributing structure. As discussed above, the gas distributingstructure in an embodiment may have one or more openings 764 to allowcompressed gas to adequately flow into and be distributed around thecircumference of the back surface 728 of the orbiting scroll 714.

In an embodiment, the opening 764 may be provided on the surface 766 ofbearing support member 758 instead of the orbiting scroll 714. In suchan embodiment, the compressor 700 may include a pathway, which extendsin part through the bearing support member 758 to provide compressedgas. For example, the pathway in such an embodiment may be similar tothe pathway 68 as shown in FIG. 2 and as described above.

As previously discussed, a scroll compressor 700 may include a booster(e.g., the booster 70 shown in FIG. 1). In an embodiment, the boostercan be fluidly connected to, for example, a pathway (e.g., pathway 768,pathway 68) or a volume (e.g., discharge volume 740, upper volume 734A,intermediate volume 717) that supply pressurized gas to the aerostaticthrust bearing. In an embodiment, the gas distributing structure mayalso include a porous material as discussed above with respect to FIG. 2or FIG. 7.

A cross-sectional view of a vertical, oil-free scroll compressor 800 isshown in FIG. 15. The scroll compressor 800 may have similar features tothe scroll compressor 700 shown in FIG. 14 and as described above,except as described herein. The oil-free scroll compressor 800 includesan aerostatic thrust bearing to support the orbiting scroll 814 in theaxial direction similar to the aerostatic thrust bearing as shown inFIG. 14 and described above. As shown in FIG. 15, the aerostatic thrustbearing in an embodiment includes a back surface 828 of the orbitingscroll 814, a surface 866 of a bearing support member 858, a gasdistributing structure having an opening 864, an outer radial seal 1820,and an inner radial seal 1810. The aerostatic thrust bearing in anembodiment may have a similar configuration to the aerostatic thrustbearing shown in FIG. 14 and as discussed above.

The compressor 800 has aerostatic bearings along the crankshaft 824. Theaerostatic bearing along the crankshaft 824 illustrated in FIG. 15 aresimilar to the aerostatic bearings along the crankshaft 524 as shown inFIG. 11 and as discussed above. In an embodiment, the configuration ofthe aerostatic bearings and the configuration for providing compressedgas to the aerostatic bearings in FIG. 15 may be similar to theaerostatic bearings as shown in FIG. 11 and as discussed above. Each ofthe aerostatic bearings along the crankshaft 824 includes a respectivegas distributing structure 848, 850, 852, 854. Each of the gasdistributing structures 848, 850, 852, 854 includes a porous material.

In an embodiment, a pathway 865 fluidly connects the discharge volume840 to the gas distributing structure 848. Accordingly, pressurized gasis provided to the aerostatic radial bearing along the eccentric end 856of the crankshaft. In an embodiment, the pathway 865 may be connected toa different volume (e.g., intermediate volume 816, intermediate volume817). In an embodiment, the pathway 865 may connect to the pathway(s)868 that provide compressed gas to the gas distributing structure 864. Apassageway 869 fluidly connects the gas distributing structures 850,852, 854 in the bearing housing 858 and lower bearing housing 859 to anupper volume 834A of the scroll compressor 800. Accordingly, pressurizedgas is supplied from the upper volume 834A to the aerostatic bearingsalong the crankshaft 824. Alternatively or additionally, the connectingpathway 869 in an embodiment may fluidly connect the gas distributingstructures 850, 852, 854 for supporting the crankshaft 524 to anexternal source of pressurized gas (e.g. booster, compressor, or thelike).

The compressor 800 shown in FIG. 15 has three aerostatic radial bearingsand one aerostatic thrust bearing along the crankshaft 824. However, anembodiment may include one or more aerostatic bearings in any specificlocation along the crankshaft 24. Bearings may be included as suitableto support the crankshaft 824 and to allow the orbiting scroll 814 to berotated and/or orbited correctly, relative to the fixed scroll 812.

In an embodiment one or more of the gas distributing structures 848,850, 852, 854 may be provided in the crankshaft 824 instead of a bearinghousing 858, 859 or the orbiting scroll 814. For example, in such anembodiment, the configuration of the aerostatic bearings and theconfiguration for providing compressed gas to the aerostatic bearings inFIG. 15 may be similar to the aerostatic bearings as shown in FIG. 8 andas discussed above. For example, in such an embodiment, theconfiguration of the aerostatic bearings and the configuration forproviding compressed gas to the aerostatic bearings in FIG. 15 may besimilar to the aerostatic bearings as shown in FIG. 12 and as discussedabove.

Aspects:

Any of aspects 1-16 can be combined with any of aspects 17-39, and anyof aspects 17-21 can be combined with any of aspects 22-39.

-   Aspect 1. A scroll compressor, comprising:

a first scroll member having a baseplate and a spiral wrap that projectsfrom a surface of the baseplate;

a second scroll member having a baseplate and a spiral wrap thatprojects from a surface of the baseplate;

an aerostatic thrust bearing that supports the second scroll member inthe axial direction and includes: a surface of the second scroll member,a surface of a fixed supporting member, and a gas distributingstructure, wherein

a source of pressurized gas supplies pressurized gas to the gasdistributing structure; and

the gas distributing structure forms a layer of gas between the surfaceof the fixed supporting member and the surface of the second scrollmember.

-   Aspect 2. The scroll compressor of aspect 1, wherein the pressurized    gas includes gas that has been compressed by the first scroll member    and the second scroll member.-   Aspect 3. The scroll compressor of either one of aspects 1 or 2,    wherein the gas distributing structure includes two or more portions    and each portion is supplied with the pressurized gas.-   Aspect 4. The scroll compressor of any one of the aspects 1-3,    wherein an upper surface of the gas distributing structure is ring    shaped such that the gas distributing structure distributes gas    along an entire circumference of the surface of the second scroll    member.-   Aspect 5. The scroll compressor of any one of the aspects 1-4,    wherein an upper surface of the gas distributing structure is    sloped.-   Aspect 6. The scroll compressor of any of the aspects 1-5, wherein    the gas distributing structure is located on the back surface of the    second scroll member.-   Aspect 7. The scroll compressor of any one of aspects 1-6, further    comprising:

a pathway within the second scroll member that fluidly connects a volumebetween the first scroll member and the second scroll member to the gasdistributing structure, wherein

the volume between the first scroll member and the second scroll memberis the source of the pressurized gas.

-   Aspect 8. The scroll compressor of any one of aspects 1-5, wherein    the gas distributing structure is located on the surface of the    fixed supporting member.-   Aspect 9. The scroll compressor of any one of aspects 1-6 and 8,    further comprising:

an upper volume, wherein gas compressed by the first scroll member andsecond scroll member is discharged into the upper volume; and

a connecting pathway that fluidly connects the upper volume to the gasdistributing structure, wherein

the source of pressurized gas is the upper volume.

-   Aspect 10. The scroll compressor of any one of the aspects 1-9,    wherein the source of pressurized gas includes an external source of    pressurized gas.-   Aspect 11. The scroll compressor of any one of the aspects 1-10,    wherein the gas distributing structure includes a porous material.-   Aspect 12. The scroll compressor of any one of aspects 1-11, wherein    the gas distributing structure includes an inner radial seal and an    outer radial seal, the inner radial seal and the outer radial seal    located between the second scroll member and the fixed supporting    member.-   Aspect 13. The scroll compressor of any one of aspects 1-12, wherein    the gas distributing structure further includes one or more openings    in the back surface of the second scroll member or the surface of    the fixed supporting member, the one or more openings located    between the inner radial seal and the outer radial seal in a radial    direction of the second scroll member.-   Aspect 14. The scroll compressor of any of aspects 1-13, further    comprising:

a flow control device that controls a flow of the pressurized gassupplied to gas distributing structure

-   Aspect 15. The scroll compressor of any of the aspects 1-14, further    comprising:

a suction inlet for inlet gas;

a lower volume that is fluidly connected to an inlet of the first andsecond scroll members and fluidly connected to the suction inlet,wherein

gas flowing into the inlet of the first and second scroll membersincludes gas exited from the gas distributing structure.

-   Aspect 16. The scroll compressor of any of the aspects 1-15, further    comprising:

a booster providing a secondary source of pressurized gas for the gasdistributing structure.

-   Aspect 17. A method of supporting a rotating or orbiting scroll    member in a scroll compressor, where a fixed supporting member is    positioned within the scroll compressor such that a surface of the    fixed supporting member faces a surface of the rotating or orbiting    scroll member, the method comprising:

providing a gas distributing structure on the surface of the fixedsupporting member or the surface of the rotating or orbiting scrollmember;

supplying pressurized gas to the gas distributing structure from asource of pressurized gas; and

the gas distributing structure forming a layer of gas between therotating or orbiting scroll member and the fixed supporting member, thelayer of gas supporting a thrust load of the rotating or orbiting scrollmember.

-   Aspect 18. The method of aspect 17, wherein the gas distributing    structure includes a porous material.-   Aspect 19. The method of either aspects 17 or 18, wherein the gas    distributing structure comprises an inner radial seal and an outer    radial seal, the inner radial seal and the outer radial seal located    between the rotating or orbiting scroll member and the fixed    supporting member.-   Aspect 20. The method of any one of aspects 17-19, wherein the    source of pressurized gas includes an internal source of pressurized    gas.-   Aspect 21. The method of any one of aspects 17-20, further    comprising:

supplying pressurized gas to the gas distributing structure from asecondary source of pressurized gas when the flow rate or pressure ofthe pressurized gas from the source of pressurized gas is not largeenough to support the thrust load.

-   Aspect 22. An oil-free scroll compressor, comprising:

a first scroll member having a baseplate and a spiral wrap that projectsfrom the baseplate;

a second scroll member having a baseplate and a spiral wrap thatprojects from the baseplate;

an aerostatic thrust bearing that supports the second scroll member inan axial direction and comprises:

-   -   a back surface of the baseplate of the second scroll member,    -   a surface of a fixed supporting member, and    -   a gas distributing structure on one of the back surface of the        second scroll member or the surface of the fixed supporting        member, wherein    -   the gas distributing structure forms a layer of pressurized gas        between the back surface of the baseplate of the second scroll        member and the surface of the fixed supporting member, when        supplied with pressurized gas;

a crankshaft that rotates or orbits the second scroll member; and

an aerostatic radial bearing to support the crankshaft while thecrankshaft rotates, the aerostatic radial bearing comprising:

-   -   an outer surface of the crankshaft,    -   a supporting surface that faces the outer surface of the        crankshaft, and    -   a second gas distributing structure on one of the outer surface        of the crankshaft or the support surface, wherein    -   the gas distributing structure forms a layer of gas between the        outer surface of the crankshaft and the supporting surface that        faces the outer surface of the crankshaft, when supplied with        pressurized gas.

-   Aspect 23. The oil-free scroll compressor of aspect 22, wherein the    gas distributing structure is located on the back surface of the    second scroll member.

-   Aspect 24. The oil-free scroll compressor of either of aspects 22 or    23, further comprising:

a pathway within the second scroll member that fluidly connects a volumebetween the first scroll member and the second scroll member to the gasdistributing structure, the pathway configured to supply the pressurizedgas to the gas distributing structure from the volume between the firstscroll member and the second scroll member.

-   Aspect 25. The oil-free scroll compressor of any one of aspects    22-23, wherein the gas distributing structure is located on the    surface of the fixed supporting member.-   Aspect 26. The oil-free scroll compressor of any one of aspects 22    or 25, further comprising:

an upper volume, wherein gas compressed by the first scroll member andsecond scroll member is discharged into the upper volume; and

a connecting pathway that fluidly connects the upper volume to the gasdistributing structure, the connecting pathway configured to supply thepressurized gas to the gas distributing structure from the upper volume.

-   Aspect 27. The oil-free scroll compressor of any one of aspects    22-26, wherein the pressurized gas is supplied to the gas    distributing structure from an external source of pressurized gas.-   Aspect 28. The oil-free scroll compressor of any one of aspects    22-27, wherein the gas distributing structure includes a porous    material.-   Aspect 29. The oil-free scroll compressor of any one of aspects    22-28, wherein the gas distributing structure includes an inner    radial seal and an outer radial seal, the inner radial seal and the    outer radial seal located between the second scroll member and the    fixed supporting member.-   Aspect 30. The scroll compressor of any one of aspects 22-29,    wherein the gas distributing structure includes one or more openings    on the back surface of the second scroll member or the surface of    the fixed supporting member, the one or more openings located    between the inner radial seal and the outer radial seal in a radial    direction of the second scroll member.-   Aspect 31. The scroll compressor of any one of aspects 22-30,    further comprising:

a suction inlet for inlet gas;

a lower volume that is fluidly connected to an inlet of the first andsecond scroll members and fluidly connected to the suction inlet,wherein

gas flowing into the inlet of the first and second scroll membersincludes gas distributed by the gas distributing structure.

-   Aspect 32. The oil-free scroll compressor of any one of aspects    22-31, wherein the pressurized gas supplied to the gas distributing    structure includes gas that has been compressed by the first scroll    member and the second scroll member.-   Aspect 33. The oil-free scroll compressor of any one of aspects    22-32, wherein

the second gas distributing structure is located on the outer surface ofthe crankshaft; and

the crankshaft includes an interior gallery fluidly connected to thesecond gas distributing structure, the interior gallery configured tosupply the second gas distributing structure with the pressurized gas.

-   Aspect 34. The oil-free scroll compressor of either of any one of    aspects 22-33, further comprising:

a passageway in the baseplate of the second scroll member, thepassageway fluidly connecting a volume between the first and secondscroll members to the interior gallery of the crankshaft.

-   Aspect 35. The oil-free scroll compressor of aspect 34, wherein the    volume between the first and second scroll members is a discharge    volume of the first and second scroll members.-   Aspect 36. The oil-free scroll compressor of aspect 34, wherein the    volume between the first and second scroll members is an    intermediate volume of the first and second scroll members.-   Aspect 37. The oil-free scroll compressor of any one of aspects    22-32, wherein the second gas distributing structure is located on    the supporting surface.-   Aspect 38. The oil free scroll compressor of any one of aspects    22-37, wherein an internal source of pressurized gas supplies the    pressurized gas for the second gas distributing structure.-   Aspect 39. The oil free scroll compressor of any one of aspects    22-38, further comprising:

an aerostatic thrust bearing to support the crankshaft while thecrankshaft rotates, the aerostatic thrust bearing comprising an axialsurface of the crankshaft, a supporting surface that faces the axialsurface of the crankshaft, and a third gas distributing structure,wherein

the gas distributing structure forms a layer of gas between the axialsurface of the crankshaft and the supporting surface that faces theaxial surface of the crankshaft, when supplied with a pressurized gas.

The examples disclosed in this application are to be considered in allrespects as illustrative and not limitative. The scope of the inventionis indicated by the appended claims rather than by the foregoingdescription; and all changes which come within the meaning and range ofequivalency of the claims are intended to be embraced therein.

What is claimed is:
 1. A scroll compressor, comprising: a first scrollmember having a baseplate and a spiral wrap that projects from a surfaceof the baseplate; a second scroll member having a baseplate and a spiralwrap that projects from a surface of the baseplate; an aerostatic thrustbearing that supports the second scroll member in the axial directionand includes: a surface of the second scroll member, a surface of afixed supporting member, and a gas distributing structure, wherein asource of pressurized gas supplies pressurized gas to the gasdistributing structure; and the gas distributing structure forms a layerof gas between the surface of the fixed supporting member and thesurface of the second scroll member.
 2. The scroll compressor of claim1, wherein the pressurized gas includes gas that has been compressed bythe first scroll member and the second scroll member.
 3. The scrollcompressor of claim 1, wherein the gas distributing structure is locatedon the back surface of the second scroll member.
 4. The scrollcompressor of claim 3, further comprising: a pathway within the secondscroll member that fluidly connects a volume between the first scrollmember and the second scroll member to the gas distributing structure,wherein the volume between the first scroll member and the second scrollmember is the source of the pressurized gas.
 5. The scroll compressor ofclaim 1, wherein the gas distributing structure is located on thesurface of the fixed supporting member.
 6. The scroll compressor ofclaim 5, further comprising: an upper volume, wherein gas compressed bythe first scroll member and second scroll member is discharged into theupper volume; and a connecting pathway that fluidly connects the uppervolume to the gas distributing structure, wherein the source ofpressurized gas is the upper volume.
 7. The scroll compressor of claim1, wherein the gas distributing structure includes a porous material. 8.The scroll compressor of claim 1, wherein the gas distributing structureincludes an inner radial seal and an outer radial seal, the inner radialseal and the outer radial seal located between the second scroll memberand the fixed supporting member.
 9. The scroll compressor of claim 8,wherein the gas distributing structure further includes one or moreopenings in the back surface of the second scroll member or the surfaceof the fixed supporting member, the one or more openings located betweenthe inner radial seal and the outer radial seal in a radial direction ofthe second scroll member.
 10. The scroll compressor of claim 9, whereinthe gas distributing structure includes two or more of the one or moreopenings.
 11. The scroll compressor of claim 8, further comprising: acrankshaft that rotates or orbits the second scroll member; and anaerostatic radial bearing to support the crankshaft while the crankshaftrotates, the aerostatic radial bearing comprising: an outer surface ofthe crankshaft, a supporting surface that faces the outer surface of thecrankshaft, and a second gas distributing structure on one of the outersurface of the crankshaft or the support surface, wherein the gasdistributing structure forms a layer of gas between the outer surface ofthe crankshaft and the supporting surface that faces the outer surfaceof the crankshaft, when supplied with pressurized gas, wherein thescroll compressor is an oil-free scroll compressor.
 12. The scrollcompressor of claim 11, wherein the second gas distributing structure islocated on the outer surface of the crankshaft, and the crankshaftincludes an interior gallery fluidly connected to the second gasdistributing structure, the interior gallery configured to supply thesecond gas distributing structure with the pressurized gas.
 13. Thescroll compressor of claim 12, further comprising: a passageway in thebaseplate of the second scroll member, the passageway fluidly connectinga volume between the first and second scroll members to the interiorgallery of the crankshaft.
 14. The scroll compressor of claim 1, furthercomprising: a booster providing a secondary source of pressurized gasfor the gas distributing structure.
 15. A method of supporting arotating or orbiting scroll member in a scroll compressor, where a fixedsupporting member is positioned within the scroll compressor such that asurface of the fixed supporting member faces a surface of the rotatingor orbiting scroll member, the method comprising: providing a gasdistributing structure on the surface of the fixed supporting member orthe surface of the rotating or orbiting scroll member; supplyingpressurized gas to the gas distributing structure from a source ofpressurized gas; and the gas distributing structure forming a layer ofgas between the rotating or orbiting scroll member and the fixedsupporting member, the layer of gas supporting a thrust load of therotating or orbiting scroll member.
 16. The method of claim 15, whereinthe gas distributing structure includes a porous material, or the gasdistributing structure includes an inner radial seal and an outer radialseal, the inner radial seal and the outer radial seal located betweenthe rotating or orbiting scroll member and the fixed supporting member.17. The method of claim 16, wherein the gas distributing structureincludes one or more openings in the surface of the rotating or orbitingscroll member or the surface of the fixed supporting member, the one ormore openings located between the inner radial seal and the outer radialseal in a radial direction of the rotating or orbiting scroll member,and the pressurized gas is supplied to the gas distributing structurefrom the source of pressurized gas through the one or more openings. 18.The method of claim 15, wherein the rotating or orbiting scroll memberis intermeshed with a second scroll member, and a volume between therotating or orbiting scroll member and the second scroll member is thesource of pressurized gas.
 19. The method of claim 18, wherein thevolume between the rotating or orbiting scroll member and the secondscroll member is an intermediate volume of the rotating or orbitingscroll member and the second scroll member.
 20. The method of claim 15,further comprising: supplying pressurized gas to the gas distributingstructure from a secondary source of pressurized gas when the flow rateor pressure of the pressurized gas from the source of pressurized gas isnot large enough to support the thrust load.